Continuous analyte measurement systems and systems and methods for implanting them

ABSTRACT

Low profile continuous analyte measurement systems and systems and methods for implantation within the skin of a patient are provided.

RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 15/789,942 filed Oct. 20, 2017, which is a continuation of U.S.patent application Ser. No. 12/842,013 filed Jul. 22, 2010, now U.S.Pat. No. 9,795,326, which claims priority under 35 U.S.C. § 119(e) toU.S. Provisional Application No. 61/227,967 filed Jul. 23, 2009,entitled “Continuous Analyte Measurement Systems and Systems and Methodsfor Implanting Them”, the disclosures of each of which are incorporatedherein by reference for all purposes.

BACKGROUND

There are a number of instances when it is desirable or necessary tomonitor the concentration of an analyte, such as glucose, lactate, oroxygen, for example, in bodily fluid of a body. For example, it may bedesirable to monitor high or low levels of glucose in blood or otherbodily fluid that may be detrimental to a human. In a healthy human, theconcentration of glucose in the blood is maintained between about 0.8and about 1.2 mg/mL by a variety of hormones, such as insulin andglucagons, for example. If the blood glucose level is raised above itsnormal level, hyperglycemia develops and attendant symptoms may result.If the blood glucose concentration falls below its normal level,hypoglycemia develops and attendant symptoms, such as neurological andother symptoms, may result. Both hyperglycemia and hypoglycemia mayresult in death if untreated. Maintaining blood glucose at anappropriate concentration is thus a desirable or necessary part oftreating a person who is physiologically unable to do so unaided, suchas a person who is afflicted with diabetes mellitus.

Certain compounds may be administered to increase or decrease theconcentration of blood glucose in a body. By way of example, insulin canbe administered to a person in a variety of ways, such as throughinjection, for example, to decrease that person's blood glucoseconcentration. Further by way of example, glucose may be administered toa person in a variety of ways, such as directly, through injection oradministration of an intravenous solution, for example, or indirectly,through ingestion of certain foods or drinks, for example, to increasethat person's blood glucose level.

Regardless of the type of adjustment used, it is typically desirable ornecessary to determine a person's blood glucose concentration beforemaking an appropriate adjustment. Typically, blood glucose concentrationis monitored by a person or sometimes by a physician using an in vitrotest that requires a blood sample. The person may obtain the bloodsample by withdrawing blood from a blood source in his or her body, suchas a vein, using a needle and syringe, for example, or by lancing aportion of his or her skin, using a lancing device, for example, to makeblood available external to the skin, to obtain the necessary samplevolume for in vitro testing. The fresh blood sample is then applied toan in vitro testing device such as an analyte test strip, whereuponsuitable detection methods, such as colorimetric, electrochemical, orphotometric detection methods, for example, may be used to determine theperson's actual blood glucose level. The foregoing procedure provides ablood glucose concentration for a particular or discrete point in time,and thus, must be repeated periodically, in order to monitor bloodglucose over a longer period.

Conventionally, a “finger stick” is generally performed to extract anadequate volume of blood from a finger for in vitro glucose testingsince the tissue of the fingertip is highly perfused with blood vessels.These tests monitor glucose at discrete periods of time when anindividual affirmatively initiates a test at a given point in time, andtherefore may be characterized as “discrete” tests. Unfortunately, thefingertip is also densely supplied with pain receptors, which can leadto significant discomfort during the blood extraction process.Unfortunately, the consistency with which the level of glucose ischecked varies widely among individuals. Many diabetics find theperiodic testing inconvenient and they sometimes forget to test theirglucose level or do not have time for a proper test. Further, as thefingertip is densely supplied with pain receptors which causessignificant discomfort during the blood extraction process, someindividuals will not be inclined to test their glucose levels asfrequently as they should. These situations may result in hyperglycemicor hypoglycemic episodes.

Glucose monitoring systems that allow for sample extraction from sitesother than the finger and/or that can operate using small samples ofblood, have been developed. (See, e.g., U.S. Pat. Nos. 6,120,676,6,591,125 and 7,299,082, the disclosures of each of which areincorporated herein by reference for all purposes). Typically, about oneμL or less of sample may be required for the proper operation of thesedevices, which enables glucose testing with a sample of blood obtainedfrom the surface of a palm, a hand, an arm, a thigh, a leg, the torso,or the abdomen. Even though less painful than the finger stick approach,these other sample extraction methods are still inconvenient and mayalso be somewhat painful.

In addition to the discrete, in vitro, blood glucose monitoring systemsdescribed above, at least partially implantable, or in vivo, bloodglucose monitoring systems, which are designed to provide continuous orsemi-continuous in vivo measurement of an individual's glucoseconcentration, have been described. See, e.g., U.S. Pat. Nos. 6,175,752,6,284,478, 6,134,461, 6,560,471, 6,746,582, 6,579,690, 6,932,892 and7,299,082, the disclosures of each of which are incorporated herein byreference for all purposes.

A number of these in vivo systems are based on “enzyme electrode”technology, whereby an enzymatic reaction involving an enzyme such asglucose oxidase, glucose dehydrogenase, or the like, is combined with anelectrochemical sensor for the determination of an individual's glucoselevel in a sample of the individual's biological fluid. By way ofexample, the electrochemical sensor may be placed in substantiallycontinuous contact with a blood source, e.g., may be inserted into ablood source, such as a vein or other blood vessel, for example, suchthat the sensor is in continuous contact with blood and can effectivelymonitor blood glucose levels. Further by way of example, theelectrochemical sensor may be placed in substantially continuous contactwith bodily fluid other than blood, such as dermal or subcutaneousfluid, for example, for effective monitoring of glucose levels in suchbodily fluid, such as interstitial fluid.

Relative to discrete or periodic monitoring using analyte test strips,continuous monitoring is generally more desirable in that it may providea more comprehensive assessment of glucose levels and more usefulinformation, including predictive trend information, for example.Subcutaneous continuous glucose monitoring is also desirable as it istypically less invasive than continuous glucose monitoring in bloodaccessed from a blood vessel.

Regardless of the type of implantable analyte monitoring deviceemployed, it has been observed that transient, low sensor readings whichresult in clinically significant sensor related errors may occur for aperiod of time. For example, it has been found that during the initial12-24 hours of sensor operation (after implantation), a glucose sensor'ssensitivity (defined as the ratio between the analyte sensor currentlevel and the blood glucose level) may be relatively low—a phenomenonsometimes referred to as “early signal attenuation” (ESA). Additionally,low sensor readings may be more likely to occur at certain predictabletimes such as during night time use—commonly referred to as “night timedrop outs”. An in vivo analyte sensor with lower than normal sensitivitymay report blood glucose values lower than the actual values, thuspotentially underestimating hyperglycemia, and triggering falsehypoglycemia alarms.

While these transient, low readings are infrequent and, in manyinstances, resolve after a period of time, the negative deviations insensor readings impose constraints upon analyte monitoring during theperiod in which the deviations are observed. One manner of addressingthis problem is to configure the analyte monitoring system so as todelay reporting readings to the user until after this period of negativedeviations passes. However, this leaves the user vulnerable and relyingon alternate means of analyte measuring, e.g., in vitro testing, duringthis time. Another way of addressing negative deviations in sensorsensitivity is to require frequent calibration of the sensor during thetime period in which the sensor is used. This is often accomplished inthe context of continuous glucose monitoring devices by using areference value after the sensor has been positioned in the body, wherethe reference value most often employed is obtained by a finger stickand use of a blood glucose test strip. However, these multiplecalibrations are not desirable for at least the reasons that they areinconvenient and painful, as described above.

One cause of spurious low readings or drop outs by these implantablesensors is thought to be the presence of blood clots, also known as“thrombi”, formed as a result of insertion of the sensor in vivo. Suchclots exist in close proximity to a subcutaneous glucose sensor and havea tendency to “consume” glucose at a high rate, thereby lowering thelocal glucose concentration. It may also be that the implanted sensorconstricts adjacent blood vessels thereby restricting glucose deliveryto the sensor site.

One approach to addressing the problem of drop outs is to reduce thesize of the sensor, thereby reducing the likelihood of thrombusformation upon implantation and impingement of the sensor structure onadjacent blood vessels, and thus, maximizing fluid flow to the sensor.One manner of reducing the size or surface area of at least theimplantable portion of a sensor is to provide a sensor in which thesensor's electrodes and other sensing components and/or layers aredistributed over both sides of the sensor, thereby necessitating anarrow sensor profile. Examples of such double-sided sensors aredisclosed in U.S. Pat. No. 6,175,752, U.S. Patent ApplicationPublication No. 2007/0203407, now U.S. Pat. No. 7,826,879, and U.S.Provisional Application No. 61/165,499 filed Mar. 31, 2009, thedisclosures of each of which are incorporated herein by reference forall purposes.

It would also be desirable to provide sensors for use in a continuousanalyte monitoring system that have negligible variations insensitivity, including no variations or at least no statisticallysignificant and/or clinically significant variations, from sensor tosensor. Such sensors would have to lend themselves to being highlyreproducible and would necessarily involve the use of extremely accuratefabrication processes.

It would also be highly advantageous to provide continuous analytemonitoring systems that are substantially impervious to, or at leastminimize, spurious low readings due to the in vivo environmental effectsof subcutaneous implantation, such as ESA and night-time dropouts. Ofparticular interest are analyte monitoring devices and systems that arecapable of substantially immediate and accurate analyte reporting to theuser so that spurious low readings, or frequent calibrations, areminimized or are non existent.

It would also be highly advantageous if such sensors had a constructwhich makes them even less invasive than currently available sensors andwhich further minimizes pain and discomfort to the user.

SUMMARY

Embodiments of the present disclosure include continuous analytemonitoring systems utilizing implantable or partially implantableanalyte sensors which have a relatively small profile (as compared tocurrently available implantable sensors). The relatively small size ofthe subject sensors reduce the likelihood of bleeding and, therefore,minimize thrombus formation upon implantation and the impingement of thesensor structure on adjacent blood vessels, and thus, maximizing fluidflow to the sensor and reducing the probability of ESA or low sensorreadings.

In certain embodiments, the sensors are double-sided, meaning that bothsides of the sensor's substrate are electrochemically functional, i.e.,each side provides at least one electrode, thereby reducing thenecessary surface area of the sensor. This enables the sensors to have arelatively smaller insertable distal or tail portion which reduces thein vivo environmental effects to which they are subjected. Further, thenon-insertable proximal or external portion of the sensor may also havea relatively reduced size.

The subject continuous analyte monitoring systems include a skin-mountedportion or assembly and a remote portion or assembly. The skin-mountedportion includes at least the data transmitter, the transmitter battery,a portion of the sensor electronics, and electrical contacts forelectrically coupling the implanted sensor with the transmitter. Theremote portion of the system includes at least a data receiver and auser interface which may also be configured for test strip-based glucosemonitoring. The skin-mounted portion of the system has a housing or basewhich is constructed to externally mount to the patient's skin and tomechanically and electrically couple the implanted sensor with thetransmitter. Removably held or positioned within the housing/basestructure is a connector piece having an electrical contactconfiguration which, when used with a double-sided sensor, enablescoupling of the sensor to the transmitter in a low-profile,space-efficient manner. The skin-mounted components of the system,including the associated mounting/coupling structure, have complementarydiminutive structures which, along with the very small sensor, whichmaximize patient usability and comfort.

Embodiments further include systems and devices for implanting thesubject analyte sensors within a patient's skin and simultaneouslycoupling the analyte monitoring system's external, skin-mounted unit tothe implanted sensor. Certain insertion systems include at least amanually-held and/or manually-operated inserter device and an insertionneedle which is carried by and removably coupled to the inserter. Incertain of these embodiments, only the insertion needle is disposablewith the inserter or insertion gun being reusable, reducing the overallcost of the system and providing environmental advantages. In otherembodiments, the skin-mounted unit and sensor are inserted manuallywithout the use of an insertion device.

Embodiments of the subject continuous analyte monitoring systems mayinclude additional features and advantages. For example, certainembodiments do not require individual-specific calibration by the user,and, in certain of these embodiments, require no factory-basedcalibration as well. Certain other embodiments of the continuous analytemonitoring systems are capable of substantially immediate and accurateanalyte reporting to the user so that spurious low readings, or frequentcalibrations, are minimized or are non-existent.

The subject analyte sensors usable with the subject continuous analytemonitoring systems are highly reproducible with negligible or virtuallynon-existent sensor-to-sensor variations with respect to sensitivity tothe analyte, eliminating the need for user-based calibration.Furthermore, in certain embodiments, the analyte sensors have apredictable sensitivity drift on the shelf and/or during in vivo use areprovided. Computer programmable products including devices and/orsystems that include programming for a given sensor drift profile mayalso be provided. The programming may use the drift profile to apply acorrection factor to the system to eliminate the need for user-basedcalibration.

These and other features, objects and advantages of the presentdisclosure will become apparent to those persons skilled in the art uponreading the details of the present disclosure as more fully describedbelow.

INCORPORATION BY REFERENCE

The following patents, applications and/or publications are incorporatedherein by reference for all purposes: U.S. Pat. Nos. 4,545,382;4,711,245; 5,262,035; 5,262,305; 5,264,104; 5,320,715; 5,356,786;5,509,410; 5,543,326; 5,593,852; 5,601,435; 5,628,890; 5,820,551;5,822,715; 5,899,855; 5,918,603; 6,071,391; 6,103,033; 6,120,676;6,121,009; 6,134,461; 6,143,164; 6,144,837; 6,161,095; 6,175,752;6,270,455; 6,284,478; 6,299,757; 6,338,790; 6,377,894; 6,461,496;6,503,381; 6,514,460; 6,514,718; 6,540,891; 6,560,471; 6,579,690;6,591,125; 6,592,745; 6,600,997; 6,605,200; 6,605,201; 6,616,819;6,618,934; 6,650,471; 6,654,625; 6,676,816; 6,730,200; 6,736,957;6,746,582; 6,749,740; 6,764,581; 6,773,671; 6,881,551; 6,893,545;6,932,892; 6,932,894; 6,942,518; 7,041,468; 7,167,818; and 7,299,082;U.S. Published Application Nos. 2004/0186365, now U.S. Pat. No.7,811,231; 2005/0182306, now U.S. Pat. No. 8,771,183; 2006/0025662, nowU.S. Pat. No. 7,740,581; 2006/0091006; 2007/0056858, now U.S. Pat. No.8,298,389; 2007/0068807, now U.S. Pat. No. 7,846,311; 2007/0095661;2007/0108048, now U.S. Pat. No. 7,918,975; 2007/0199818, now U.S. Pat.No. 7,811,430; 2007/0227911, now U.S. Pat. No. 7,887,682; 2007/0233013;2008/0066305, now U.S. Pat. No. 7,895,740; 2008/0081977, now U.S. Pat.No. 7,618,369; 2008/0102441, now U.S. Pat. No. 7,822,557; 2008/0148873,now U.S. Pat. No. 7,802,467; 2008/0161666; 2008/0267823; and2009/0054748, now U.S. Pat. No. 7,885,698; U.S. patent application Ser.No. 11/461,725, now U.S. Pat. No. 7,866,026; Ser. Nos. 12/131,012;12/242,823, now U.S. Pat. No. 8,219,173; Ser. No. 12/363,712, now U.S.Pat. No. 8,346,335; Ser. Nos. 12/495,709; 12/698,124; and 12/714,439;U.S. Provisional Application Ser. Nos. 61/184,234; 61/230,686; and61/347,754.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of various aspects, features and embodiments ofthe present disclosure is provided herein with reference to theaccompanying drawings, which are briefly described below. The drawingsare illustrative and are not necessarily drawn to scale, with somecomponents and features being exaggerated for clarity. The drawingsillustrate various aspects and features of the present disclosure andmay illustrate one or more embodiment(s) or example(s) of the presentdisclosure in whole or in part. A reference numeral, letter, and/orsymbol that is used in one drawing to refer to a particular element orfeature maybe used in another drawing to refer to a like element orfeature. Included in the drawings are the following:

FIG. 1 shows a block diagram of an embodiment of a data monitoring andmanagement system usable with the continuous analyte monitoring systemsof the present disclosure;

FIG. 2 shows a block diagram of an embodiment of a transmitter unit ofthe data monitoring and management system of FIG. 1;

FIG. 3 shows a block diagram of an embodiment of the receiver/monitorunit of the data monitoring and management system of FIG. 1;

FIG. 4 shows a schematic diagram of an embodiment of an analyte sensorusable with the present disclosure;

FIGS. 5A and 5B show perspective and cross sectional views,respectively, of an embodiment of an analyte sensor usable with thepresent disclosure;

FIGS. 6A, 6B and 6C show top, bottom and cross-sectional side views,respectively, of an embodiment of a two-sided analyte sensor usable withthe present disclosure;

FIGS. 7A, 7B and 7C show top, bottom and cross-sectional side views,respectively, of another embodiment of a two-sided analyte sensor usablewith the present disclosure;

FIGS. 8A and 8B show perspective and top views, respectively, of oneembodiment of a continuous analyte monitoring system of the presentdisclosure utilizing a double-sided analyte sensor;

FIGS. 9A-9E show various views of another embodiment of a continuousanalyte monitoring system of the present disclosure utilizing adifferent double-sided analyte sensor; specifically, FIG. 9A is across-sectional view of the system's control unit, including thetransmitter, on-skin mounting structure, and an electrical/mechanicalconnector with an analyte sensor operatively attached thereto; FIG. 9Bis an exploded view of the connector and analyte sensor; FIG. 9C is anexploded, partial cutaway view of the mechanical/electrical connectorand the analyte sensor; FIG. 9D is a lengthwise cross-sectional view ofthe cutaway portion of the connector taken along lines D-D of FIG. 9C;FIG. 9E is a cross-sectional view of the coupling core, taken alonglines E-E of FIG. 9C, and associated pins of the system's transmitter;

FIGS. 10A-10F are schematic representations illustrating use of aninsertion system of the present disclosure to insert the continuousanalyte monitoring system of FIGS. 9A-9E on/in the skin of a patient;

FIGS. 11A and 11B show side and top views, respectively, of an insertionneedle of the insertion system of FIGS. 10A-10F having the double-sidedanalyte sensor of FIGS. 9A-9E operatively nested therein; and

FIGS. 12A and 12B are top and bottom perspective views of anothercontinuous analyte monitoring system of the present disclosure.

DETAILED DESCRIPTION

Before the embodiments of the present disclosure are described, it is tobe understood that the present disclosure is not limited to particularembodiments described, as such may, of course, vary. It is also to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only, and is not intended to belimiting, since the scope of the present disclosure will be limited onlyby the appended claims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range and any other stated or intervening value in thatstated range, is encompassed within embodiments of the presentdisclosure. The upper and lower limits of these smaller ranges mayindependently be included in the smaller ranges as also encompassedwithin embodiments of the present disclosure, subject to anyspecifically excluded limit in the stated range. Where the stated rangeincludes one or both of the limits, ranges excluding either or both ofthose included limits are also included in the present disclosure.

Generally, embodiments of the present disclosure relate to methods anddevices for detecting at least one analyte, such as glucose, in bodyfluid. Embodiments relate to the continuous and/or automatic in vivomonitoring of the level of one or more analytes using a continuousanalyte monitoring system that includes an analyte sensor for the invivo detection, of an analyte, such as glucose, lactate, and the like,in a body fluid. Embodiments include wholly implantable analyte sensorsand analyte sensors in which only a portion of the sensor is positionedunder the skin and a portion of the sensor resides above the skin, e.g.,for contact to a control unit, transmitter, receiver, transceiver,processor, etc. At least a portion of a sensor may be, for example,subcutaneously positionable in a patient for the continuous orsemi-continuous monitoring of a level of an analyte in a patient'sinterstitial fluid. For the purposes of this description,semi-continuous monitoring and continuous monitoring will be usedinterchangeably, unless noted otherwise. The sensor response may becorrelated and/or converted to analyte levels in blood or other fluids.In certain embodiments, an analyte sensor may be positioned in contactwith interstitial fluid to detect the level of glucose, which detectedglucose may be used to infer the glucose level in the patient'sbloodstream. Analyte sensors may be insertable into a vein, artery, orother portion of the body containing fluid. Embodiments of the analytesensors of the subject disclosure may be configured for monitoring thelevel of the analyte over a time period which may range from minutes,hours, days, weeks, or longer.

FIG. 1 shows a data monitoring and management system such as, forexample, an analyte (e.g., glucose) monitoring system 100 in accordancewith certain embodiments. Embodiments of the subject disclosure arefurther described primarily with respect to glucose monitoring devicesand systems, and methods of glucose detection, for convenience only andsuch description is in no way intended to limit the scope of the presentdisclosure. It is to be understood that the analyte monitoring systemmay be configured to monitor a variety of analytes instead of or inaddition to glucose, e.g., at the same time or at different times.

Analytes that may be monitored include, but are not limited to, acetylcholine, amylase, bilirubin, cholesterol, chorionic gonadotropin,creatine kinase (e.g., CK-MB), creatine, creatinine, DNA, fructosamine,glucose, glutamine, growth hormones, hormones, ketone bodies, lactate,oxygen, peroxide, prostate-specific antigen, prothrombin, RNA, thyroidstimulating hormone, and troponin. The concentration of drugs, such as,for example, antibiotics (e.g., gentamicin, vancomycin, and the like),digitoxin, digoxin, drugs of abuse, theophylline, and warfarin, may alsobe monitored. In those embodiments that monitor more than one analyte,the analytes may be monitored at the same or different times.

The analyte monitoring system 100 includes a sensor 101, a dataprocessing unit 102 connectable to the sensor 101, and a primaryreceiver unit 104 which is configured to communicate with the dataprocessing unit 102 via a communication link 103. In certainembodiments, the primary receiver unit 104 may be further configured totransmit data to a data processing terminal 105 to evaluate or otherwiseprocess or format data received by the primary receiver unit 104. Thedata processing terminal 105 may be configured to receive data directlyfrom the data processing unit 102 via a communication link which mayoptionally be configured for bi-directional communication. Further, thedata processing unit 102 may include a transmitter or a transceiver totransmit and/or receive data to and/or from the primary receiver unit104 and/or the data processing terminal 105 and/or optionally thesecondary receiver unit 106.

Also shown in FIG. 1 is an optional secondary receiver unit 106 which isoperatively coupled to the communication link 103 and configured toreceive data transmitted from the data processing unit 102. Thesecondary receiver unit 106 may be configured to communicate with theprimary receiver unit 104, as well as the data processing terminal 105.The secondary receiver unit 106 may be configured for bi-directionalwireless communication with each of the primary receiver unit 104 andthe data processing terminal 105. As discussed in further detail below,in certain embodiments the secondary receiver unit 106 may be ade-featured receiver as compared to the primary receiver, i.e., thesecondary receiver may include a limited or minimal number of functionsand features as compared with the primary receiver unit 104. As such,the secondary receiver unit 106 may include a smaller (in one or more,including all, dimensions), compact housing or embodied in a device suchas a wrist watch, arm band, etc., for example. Alternatively, thesecondary receiver unit 106 may be configured with the same orsubstantially similar functions and features as the primary receiverunit 104. The secondary receiver unit 106 may include a docking portionto be mated with a docking cradle unit for placement by, e.g., thebedside for nighttime monitoring, and/or a bi-directional communicationdevice. A docking cradle may recharge a powers supply.

Only one sensor 101, data processing unit 102 and data processingterminal 105 are shown in the embodiment of the analyte monitoringsystem 100 illustrated in FIG. 1. However, it will be appreciated by oneof ordinary skill in the art that the analyte monitoring system 100 mayinclude more than one sensor 101 and/or more than one data processingunit 102, and/or more than one data processing terminal 105. Multiplesensors may be positioned in a patient for analyte monitoring at thesame or different times. In certain embodiments, analyte informationobtained by a first positioned sensor may be employed as a comparison toanalyte information obtained by a second sensor. This may be useful toconfirm or validate analyte information obtained from one or both of thesensors. Such redundancy may be useful if analyte information iscontemplated in critical therapy-related decisions.

The analyte monitoring system 100 may be a continuous monitoring systemor semi-continuous. In a multi-component environment, each component maybe configured to be uniquely identified by one or more of the othercomponents in the system so that communication conflict may be readilyresolved between the various components within the analyte monitoringsystem 100. For example, unique IDs, communication channels, and thelike, may be used.

In certain embodiments, the sensor 101 is physically positioned inand/or on the body of a user whose analyte level is being monitored. Thesensor 101 may be configured to continuously or semi-continuously samplethe analyte level of the user automatically (without the user initiatingthe sampling), based on a programmed intervals such as, for example, butnot limited to, once every minute, once every five minutes and so on,and convert the sampled analyte level into a corresponding signal fortransmission by the data processing unit 102. The data processing unit102 is coupleable to the sensor 101 so that both devices are positionedin or on the user's body, with at least a portion of the analyte sensor101 positioned transcutaneously. The data processing unit 102 mayinclude a fixation element such as adhesive or the like to secure it tothe user's body. A mount (not shown) attachable to the user and mateablewith the unit 102 may be used. For example, a mount may include anadhesive surface. The data processing unit 102 performs data processingfunctions, where such functions may include, but are not limited to,filtering and encoding of data signals, each of which corresponds to asampled analyte level of the user, for transmission to the primaryreceiver unit 104 via the communication link 103. In one embodiment, thesensor 101 or the data processing unit 102 or a combined sensor/dataprocessing unit may be wholly implantable under the skin layer of theuser.

In certain embodiments, the primary receiver unit 104 may include asignal interface section including an radio frequency (RF) receiver andan antenna that is configured to communicate with the data processingunit 102 via the communication link 103, and a data processing sectionfor processing the received data from the data processing unit 102 suchas data decoding, error detection and correction, data clock generation,data bit recovery, etc., or any combination thereof.

In operation, the primary receiver unit 104 in certain embodiments isconfigured to synchronize with the data processing unit 102 to uniquelyidentify the data processing unit 102, based on, for example, anidentification information of the data processing unit 102, andthereafter, to continuously or semi-continuously receive signalstransmitted from the data processing unit 102 associated with themonitored analyte levels detected by the sensor 101. Referring again toFIG. 1, the data processing terminal 105 may include a personalcomputer, a portable computer such as a laptop or a handheld device(e.g., personal digital assistants (PDAs), telephone such as a cellularphone (e.g., a multimedia and Internet-enabled mobile phone such as aniPhone or similar phone), mp3 player, pager, and the like), drugdelivery device, each of which may be configured for data communicationwith the receiver via a wired or a wireless connection. Additionally,the data processing terminal 105 may further be connected to a datanetwork (not shown) for storing, retrieving, updating, and/or analyzingdata corresponding to the detected analyte level of the user.

The data processing terminal 105 may include an infusion device such asan insulin infusion pump or the like, which may be configured toadminister insulin to patients, and which may be configured tocommunicate with the primary receiver unit 104 for receiving, amongothers, the measured analyte level. Alternatively, the primary receiverunit 104 may be configured to integrate an infusion device therein sothat the primary receiver unit 104 is configured to administer insulin(or other appropriate drug) therapy to patients, for example, foradministering and modifying basal profiles, as well as for determiningappropriate boluses for administration based on, among others, thedetected analyte levels received from the data processing unit 102. Aninfusion device may be an external device or an internal device (whollyimplantable in a user).

In certain embodiments, the data processing terminal 105, which mayinclude an insulin pump, may be configured to receive the analytesignals from the data processing unit 102, and thus, incorporate thefunctions of the primary receiver unit 104 including data processing formanaging the patient's insulin therapy and analyte monitoring. Incertain embodiments, the communication link 103 as well as one or moreof the other communication interfaces shown in FIG. 1, may use one ormore of: an RF communication protocol, an infrared communicationprotocol, a Bluetooth® enabled communication protocol, an 802.11xwireless communication protocol, or an equivalent wireless communicationprotocol which would allow secure, wireless communication of severalunits (for example, per HIPAA requirements), while avoiding potentialdata collision and interference.

FIG. 2 shows a block diagram of an embodiment of a data processing unitof the data monitoring and detection system shown in FIG. 1. User inputand/or interface components may be included or a data processing unitmay be free of user input and/or interface components. Referring to theFigure, the transmitter unit 102 in one embodiment includes an analoginterface 201 configured to communicate with the sensor 101 (FIG. 1), auser input 202, and a temperature detection section 203, each of whichis operatively coupled to a transmitter processor 204 such as a centralprocessing unit (CPU). In certain embodiments, one or moreapplication-specific integrated circuits (ASIC) may be used to implementone or more functions or routines associated with the operations of thedata processing unit (and/or receiver unit) using for example one ormore state machines and buffers.

As can be seen in the embodiment of FIG. 2, the sensor 101 (FIG. 1)includes four contacts, three of which are electrodes—work electrode (W)210, reference electrode (R) 212, and counter electrode (C) 213, eachoperatively coupled to the analog interface 201 of the data processingunit 102. This embodiment also shows optional guard contact (G) 211.Fewer or greater electrodes may be employed. For example, the counterand reference electrode functions may be served by a singlecounter/reference electrode, there may be more than one workingelectrode and/or reference electrode and/or counter electrode, etc. Alsoshown is a leak detection circuit 214 coupled to the guard contact (G)211 and the processor 204 in the transmitter unit 102 of the analytemonitoring system 100. The leak detection circuit 214 in accordance withone embodiment of the present disclosure may be configured to detectleakage current in the sensor 101 to determine whether the measuredsensor data is corrupt or whether the measured data from the sensor 101is accurate. Further shown in FIG. 2 are a transmitter serialcommunication section 205 and an RF transmitter 206, each of which isalso operatively coupled to the transmitter processor 204. Moreover, apower supply 207 such as a battery is also provided in the transmitterunit 102 to provide the necessary power for the transmitter unit 102.Additionally, as can be seen from the Figure, clock 208 is provided to,among others, supply real time information to the transmitter processor204. In one embodiment, a unidirectional input path is established fromthe sensor 101 (FIG. 1) and/or manufacturing and testing equipment tothe analog interface 201 of the transmitter unit 102, while aunidirectional output is established from the output of the RFtransmitter 206 of the transmitter unit 102 for transmission to theprimary receiver unit 104. In this manner, a data path is shown in FIG.2 between the aforementioned unidirectional input and output via adedicated link 209 from the analog interface 201 to serial communicationsection 205, thereafter to the processor 204, and then to the RFtransmitter 206.

FIG. 3 is a block diagram of an embodiment of a receiver/monitor unitsuch as the primary receiver unit 104 of the data monitoring andmanagement system shown in FIG. 1. The primary receiver unit 104 mayinclude one or more of: a blood glucose test strip interface 301 for invitro testing, an RF receiver 302, an input 303, a temperature monitorsection 304, and a clock 305, each of which is operatively coupled to aprocessing and storage section 307. The primary receiver unit 104 alsoincludes a power supply 306 operatively coupled to a power conversionand monitoring section 308. Further, the power conversion and monitoringsection 308 is also coupled to the receiver processor 307. Moreover,also shown are a receiver serial communication section 309, and anoutput 310, each operatively coupled to the processing and storage unit307. The receiver may include user input and/or interface components ormay be free of user input and/or interface components.

In certain embodiments having a test strip interface 301, the interfaceincludes a glucose level testing portion to receive a blood (or otherbody fluid sample) glucose test or information related thereto. Forexample, the interface may include a test strip port to receive aglucose test strip. The device may determine the glucose level of thetest strip, and optionally display (or otherwise notice) the glucoselevel on the output 310 of the primary receiver unit 104. Any suitabletest strip may be employed, e.g., test strips that only require a verysmall amount (e.g., one microliter or less, e.g., 0.5 microliter orless, e.g., 0.1 microliter or less), of applied sample to the strip inorder to obtain accurate glucose information, e.g. Freestyle® andPrecision® blood glucose test strips from Abbott Diabetes Care Inc.Glucose information obtained by the in vitro glucose testing device maybe used for a variety of purposes, computations, etc. For example, theinformation may be used to calibrate sensor 101 (however, calibration ofthe subject sensors may not be necessary), confirm results of the sensor101 to increase the confidence thereof (e.g., in instances in whichinformation obtained by sensor 101 is employed in therapy relateddecisions), etc. Exemplary blood glucose monitoring systems aredescribed, e.g., in U.S. Pat. Nos. 6,071,391, 6,120,676, 6,338,790 and6,616,819, and in U.S. application Ser. Nos. 11/282,001, now U.S. Pat.No. 7,918,975 and Ser. No. 11/225,659, now U.S. Pat. No. 8,298,389, thedisclosures of each of which are incorporated herein by reference forall purposes.

In further embodiments, the data processing unit 102 and/or the primaryreceiver unit 104 and/or the secondary receiver unit 106, and/or thedata processing terminal/infusion section 105 may be configured toreceive the blood glucose value from a wired connection or wirelesslyover a communication link from, for example, a blood glucose meter. Infurther embodiments, a user manipulating or using the analyte monitoringsystem 100 (FIG. 1) may manually input the blood glucose value using,for example, a user interface (for example, a keyboard, keypad, voicecommands, and the like) incorporated in the one or more of the dataprocessing unit 102, the primary receiver unit 104, secondary receiverunit 106, or the data processing terminal/infusion section 105.

Additional detailed descriptions are provided in U.S. Pat. Nos.5,262,035, 5,262,305, 5,264,104, 5,320,715, 5,593,852, 6,103,033,6,134,461, 6,175,752, 6,560,471, 6,579,690, 6,605,200, 6,654,625,6,746,582 and 6,932,894, and in U.S. Published Patent Application Nos.2004/0186365, now U.S. Pat. No. 7,811,231 and 2005/0182306, now U.S.Pat. No. 8,771,183, the disclosures of each of which are incorporatedherein by reference for all purposes.

FIG. 4 schematically shows an embodiment of an analyte sensor usable inthe continuous analyte monitoring systems just described. This sensorembodiment includes electrodes 401, 402 and 403 on a base 404.Electrodes (and/or other features) may be applied or otherwise processedusing any suitable technology, e.g., chemical vapor deposition (CVD),physical vapor deposition, sputtering, reactive sputtering, printing,coating, ablating (e.g., laser ablation), painting, dip coating, etchingand the like. Suitable conductive materials include but are not limitedto aluminum, carbon (such as graphite), cobalt, copper, gallium, gold,indium, iridium, iron, lead, magnesium, mercury (as an amalgam), nickel,niobium, osmium, palladium, platinum, rhenium, rhodium, selenium,silicon (e.g., doped polycrystalline silicon), silver, tantalum, tin,titanium, tungsten, uranium, vanadium, zinc, zirconium, mixturesthereof, and alloys, oxides, or metallic compounds of these elements.

The sensor may be wholly implantable in a user or may be configured sothat only a portion is positioned within (internal) a user and anotherportion outside (external) a user. For example, the sensor 400 mayinclude a portion positionable above a surface of the skin 410, and aportion positioned below the skin. In such embodiments, the externalportion may include contacts (connected to respective electrodes of thesecond portion by traces) to connect to another device also external tothe user such as a transmitter unit. While the embodiment of FIG. 4shows three electrodes side-by-side on the same surface of base 404,other configurations are contemplated, e.g., fewer or greaterelectrodes, some or all electrodes on different surfaces of the base orpresent on another base, some or all electrodes stacked together, someor all electrodes twisted together (e.g., an electrode twisted around orabout another or electrodes twisted together), electrodes of differingmaterials and dimensions, etc.

FIG. 5A shows a perspective view of an embodiment of an electrochemicalanalyte sensor 500 of the present disclosure having a first portion(which in this embodiment may be characterized as a major or bodyportion) positionable above a surface of the skin 510, and a secondportion (which in this embodiment may be characterized as a minor ortail portion) that includes an insertion tip 530 positionable below theskin, e.g., penetrating through the skin and into, e.g., the dermalspace 520, in contact with the user's biofluid such as interstitialfluid. Contact portions of a working electrode 501, a referenceelectrode 502, and a counter electrode 503 are positioned on the portionof the sensor 500 situated above the skin surface 510. Working electrode501, a reference electrode 502, and a counter electrode 503 are shown atthe second section and particularly at the insertion tip 530. Traces maybe provided from the electrode at the tip to the contact, as shown inFIG. 5A. It is to be understood that greater or fewer electrodes may beprovided on a sensor. For example, a sensor may include more than oneworking electrode and/or the counter and reference electrodes may be asingle counter/reference electrode, etc.

FIG. 5B shows a cross sectional view of a portion of the sensor 500 ofFIG. 5A. The electrodes 501, 502 and 503 of the sensor 500 as well asthe substrate and the dielectric layers are provided in a layeredconfiguration or construction. For example, as shown in FIG. 5B, in oneaspect, the sensor 500 (such as the sensor 101 FIG. 1), includes asubstrate layer 504, and a first conducting layer 501 such as carbon,gold, etc., disposed on at least a portion of the substrate layer 504,and which may provide the working electrode. Also shown disposed on atleast a portion of the first conducting layer 501 is a sensing componentor layer 508, discussed in greater detail below. The area of theconducting layer covered by the sensing layer is herein referred to asthe active area. A first insulation layer such as a first dielectriclayer 505 is disposed or layered on at least a portion of the firstconducting layer 501, and further, a second conducting layer 502 may bedisposed or stacked on top of at least a portion of the first insulationlayer (or dielectric layer) 505, and which may provide the referenceelectrode. In one aspect, conducting layer 502 may include a layer ofsilver/silver chloride (Ag/AgCl), gold, etc. A second insulation layer506 such as a dielectric layer in one embodiment may be disposed orlayered on at least a portion of the second conducting layer 509.Further, a third conducting layer 503 may provide the counter electrode503. It may be disposed on at least a portion of the second insulationlayer 506. Finally, a third insulation layer 507 may be disposed orlayered on at least a portion of the third conducting layer 503. In thismanner, the sensor 500 may be layered such that at least a portion ofeach of the conducting layers is separated by a respective insulationlayer (for example, a dielectric layer). The embodiment of FIGS. 5A and5B show the layers having different lengths. Some or all of the layersmay have the same or different lengths and/or widths.

In addition to the electrodes, sensing layer and dielectric layers,sensor 500 may also include a temperature probe, a mass transportlimiting layer, a biocompatible layer, and/or other optional components(none of which are illustrated). Each of these components enhances thefunctioning of and/or results from the sensor.

Substrate 504 may be formed using a variety of non-conducting materials,including, for example, polymeric or plastic materials and ceramicmaterials. (It is to be understood that substrate includes anydielectric material of a sensor, e.g., around and/or in betweenelectrodes of a sensor such as a sensor in the form of a wire whereinthe electrodes of the sensor are wires that are spaced-apart by asubstrate). In some embodiments, the substrate is flexible. For example,if the sensor is configured for implantation into a patient, then thesensor may be made flexible (although rigid sensors may also be used forimplantable sensors) to reduce pain to the patient and damage to thetissue caused by the implantation of and/or the wearing of the sensor. Aflexible substrate often increases the patient's comfort and allows awider range of activities. Suitable materials for a flexible substrateinclude, for example, non-conducting plastic or polymeric materials andother non-conducting, flexible, deformable materials. Examples of usefulplastic or polymeric materials include thermoplastics such aspolycarbonates, polyesters (e.g., Mylar™ and polyethylene terephthalate(PET)), polyvinyl chloride (PVC), polyurethanes, polyethers, polyamides,polyimides, or copolymers of these thermoplastics, such as PETG(glycol-modified polyethylene terephthalate).

In other embodiments, the sensors, or at least a portion of the sensors,are made using a relatively rigid substrate, for example, to providestructural support against bending or breaking. Examples of rigidmaterials that may be used as the substrate include poorly conductingceramics, such as aluminum oxide and silicon dioxide. One advantage ofan implantable sensor having a rigid substrate is that the sensor 500may have a sharp point and/or a sharp edge to aid in implantation of asensor without an additional insertion device. It will be appreciatedthat for many sensors and sensor applications, both rigid and flexiblesensors will operate adequately. The flexibility of the sensor may alsobe controlled and varied along a continuum by changing, for example, thecomposition and/or thickness and/or width of the substrate (and/or thecomposition and/or thickness and/or width of one or more electrodes orother material of a sensor).

In addition to considerations regarding flexibility, it is oftendesirable that implantable sensors should have a substrate which isnon-toxic. For example, the substrate may be approved by one or moreappropriate governmental agencies or private groups for in vivo use.

Although the sensor substrate, in at least some embodiments, has uniformdimensions along the entire length of the sensor, in other embodiments,the substrate has a distal end or tail portion and a proximal end orbody portion with different widths, respectively, as illustrated in FIG.5A. In these embodiments, the distal end 530 of the sensor may have arelatively narrow width. For in vivo sensors which are implantable intothe subcutaneous tissue or another portion of a patient's body, thenarrow width of the distal end of the substrate may facilitate theimplantation of the sensor. Often, the narrower the width of the sensor,the less pain the patient will feel during implantation of the sensorand afterwards.

For subcutaneously implantable sensors which are designed for continuousor semi-continuous monitoring of the analyte during normal activities ofthe patient, a tail portion or distal end of the sensor which is to beimplanted into the patient may have a width of about 2 mm or less, e.g.,about 1 mm or less, e.g., about 0.5 mm or less, e.g., about 0.25 mm orless, e.g., about 0.15 mm or less. However, wider or narrower sensorsmay be used. The proximal end of the sensor may have a width larger thanthe distal end to facilitate the connection between the electrodecontacts and contacts on a control unit, or the width may besubstantially the same as the distal portion.

The thickness of the substrate may be determined by the mechanicalproperties of the substrate material (e.g., the strength, modulus,and/or flexibility of the material), the desired use of the sensorincluding stresses on the substrate arising from that use, as well asthe depth of any channels or indentations that may be formed in thesubstrate, as discussed below. The substrate of a subcutaneouslyimplantable sensor for continuous or semi-continuous monitoring of thelevel of an analyte while the patient engages in normal activities mayhave a thickness that ranges from about 50 μm to about 500 μm, e.g.,from about 100 μm to about 300 μm. However, thicker and thinnersubstrates may be used.

The length of the sensor may have a wide range of values depending on avariety of factors. Factors which influence the length of an implantablesensor may include the depth of implantation into the patient and theability of the patient to manipulate a small flexible sensor and makeconnections between the sensor and the sensor control unit/transmitter.A subcutaneously implantable sensor of FIG. 5A may have an overalllength ranging from about 0.3 to about 5 cm, however, longer or shortersensors may be used. The length of the tail portion of the sensor (e.g.,the portion which is subcutaneously inserted into the patient) istypically from about 0.25 to about 2 cm in length. However, longer andshorter portions may be used. All or only a part of this narrow portionmay be subcutaneously implanted into the patient. The lengths of otherimplantable sensors will vary depending, at least in part, on theportion of the patient into which the sensor is to be implanted orinserted.

Electrodes 501, 502 and 503 are formed using conductive traces disposedon the substrate 504. These conductive traces may be formed over asmooth surface of the substrate or within channels formed by, forexample, embossing, indenting or otherwise creating a depression in thesubstrate. The conductive traces may extend most of the distance along alength of the sensor, as illustrated in FIG. 5A, although this is notnecessary. For implantable sensors, particularly subcutaneouslyimplantable sensors, the conductive traces typically may extend close tothe tip of the sensor to minimize the amount of the sensor that must beimplanted.

The conductive traces may be formed on the substrate by a variety oftechniques, including, for example, photolithography, screen printing,or other impact or non-impact printing techniques. The conductive tracesmay also be formed by carbonizing conductive traces in an organic (e.g.,polymeric or plastic) substrate using a laser. A description of someexemplary methods for forming the sensor is provided in U.S. patents andapplications noted herein, including U.S. Pat. Nos. 5,262,035,6,103,033, 6,175,752 and 6,284,478, the disclosures of each of which areincorporated herein by reference for all purposes.

Another method for disposing the conductive traces on the substrateincludes the formation of recessed channels in one or more surfaces ofthe substrate and the subsequent filling of these recessed channels witha conductive material. The recessed channels may be formed by indenting,embossing, or otherwise creating a depression in the surface of thesubstrate. Exemplary methods for forming channels and electrodes in asurface of a substrate can be found in U.S. Pat. No. 6,103,033, thedisclosure of which is incorporated herein by reference for allpurposes. The depth of the channels is typically related to thethickness of the substrate. In one embodiment, the channels have depthsin the range of about 12.5 μm to about 75 μm, e.g., about 25 μm to about50 μm.

The conductive traces are typically formed using a conductive materialsuch as carbon (e.g., graphite), a conductive polymer, a metal or alloy(e.g., gold or gold alloy), or a metallic compound (e.g., rutheniumdioxide or titanium dioxide). The formation of films of carbon,conductive polymer, metal, alloy, or metallic compound are well-knownand include, for example, chemical vapor deposition (CVD), physicalvapor deposition, sputtering, reactive sputtering, printing, coating,and painting. In embodiments in which the conductive material is filledinto channels formed in the substrate, the conductive material is oftenformed using a precursor material, such as a conductive ink or paste. Inthese embodiments, the conductive material is deposited on the substrateusing methods such as coating, painting, or applying the material usinga spreading instrument, such as a coating blade. Excess conductivematerial between the channels is then removed by, for example, running ablade along the substrate surface.

In certain embodiments, some or all of the electrodes 501, 502, 503 maybe provided on the same side of the substrate 504 in the layeredconstruction as described above, or alternatively, may be provided in aco-planar manner such that two or more electrodes may be positioned onthe same plane (e.g., side-by side (e.g., parallel) or angled relativeto each other) on the substrate 504. For example, co-planar electrodesmay include a suitable spacing there between and/or include dielectricmaterial or insulation material disposed between the conductinglayers/electrodes. Furthermore, in certain embodiments, one or more ofthe electrodes 501, 502, 503 may be disposed on opposing sides of thesubstrate 504. Variations of such double-sided sensors are illustratedin FIGS. 6 and 7, discussed and described in detail below. In suchdouble-sided sensor embodiments, the corresponding electrode contactsmay be on the same or different sides of the substrate. For example, anelectrode may be on a first side and its respective contact may be on asecond side, e.g., a trace connecting the electrode and the contact maytraverse through the substrate.

As noted above, analyte sensors include an analyte-responsive enzyme toprovide a sensing component or sensing layer 508 proximate to or on asurface of a working electrode in order to electrooxidize orelectroreduce the target analyte on the working electrode. Someanalytes, such as oxygen, can be directly electrooxidized orelectroreduced, while other analytes, such as glucose and lactate,require the presence of at least one component designed to facilitatethe electrochemical oxidation or reduction of the analyte. The sensinglayer may include, for example, a catalyst to catalyze a reaction of theanalyte and produce a response at the working electrode, an electrontransfer agent to transfer electrons between the analyte and the workingelectrode (or other component), or both.

In certain embodiments, the sensing layer includes one or more electrontransfer agents. Electron transfer agents that may be employed areelectroreducible and electrooxidizable ions or molecules having redoxpotentials that are a few hundred millivolts above or below the redoxpotential of the standard calomel electrode (SCE). The electron transferagent may be organic, organometallic, or inorganic. Examples of organicredox species are quinones and species that in their oxidized state havequinoid structures, such as Nile blue and indophenol. Examples oforganometallic redox species are metallocenes such as ferrocene.Examples of inorganic redox species are hexacyanoferrate (III),ruthenium hexamine etc.

In certain embodiments, electron transfer agents have structures orcharges which prevent or substantially reduce the diffusional loss ofthe electron transfer agent during the period of time that the sample isbeing analyzed. For example, electron transfer agents include, but arenot limited to, a redox species, e.g., bound to a polymer which can inturn be disposed on or near the working electrode. The bond between theredox species and the polymer may be covalent, coordinative, or ionic.Although any organic, organometallic or inorganic redox species may bebound to a polymer and used as an electron transfer agent, in certainembodiments the redox species is a transition metal compound or complex,e.g., osmium, ruthenium, iron, and cobalt compounds or complexes. Itwill be recognized that many redox species described for use with apolymeric component may also be used, without a polymeric component.

One type of polymeric electron transfer agent contains a redox speciescovalently bound in a polymeric composition. An example of this type ofmediator is poly(vinylferrocene). Another type of electron transferagent contains an ionically-bound redox species. This type of mediatormay include a charged polymer coupled to an oppositely charged redoxspecies. Examples of this type of mediator include a negatively chargedpolymer coupled to a positively charged redox species such as an osmiumor ruthenium polypyridyl cation. Another example of an ionically-boundmediator is a positively charged polymer such as quaternizedpoly(4-vinyl pyridine) or poly(1-vinyl imidazole) coupled to anegatively charged redox species such as ferricyanide or ferrocyanide.In other embodiments, electron transfer agents include a redox speciescoordinatively bound to a polymer. For example, the mediator may beformed by coordination of an osmium or cobalt 2,2′-bipyridyl complex topoly(1-vinyl imidazole) or poly(4-vinyl pyridine).

Suitable electron transfer agents are osmium transition metal complexeswith one or more ligands, each ligand having a nitrogen-containingheterocycle such as 2,2′-bipyridine, 1,10-phenanthroline, 1-methyl,2-pyridyl biimidazole, or derivatives thereof. The electron transferagents may also have one or more ligands covalently bound in a polymer,each ligand having at least one nitrogen-containing heterocycle, such aspyridine, imidazole, or derivatives thereof. One example of an electrontransfer agent includes (a) a polymer or copolymer having pyridine orimidazole functional groups and (b) osmium cations complexed with twoligands, each ligand containing 2,2′-bipyridine, 1,10-phenanthroline, orderivatives thereof, the two ligands not necessarily being the same.Some derivatives of 2,2′-bipyridine for complexation with the osmiumcation include, but are not limited to, 4,4′-dimethyl-2,2′-bipyridineand mono-, di-, and polyalkoxy-2,2′-bipyridines, such as4,4′-dimethoxy-2,2′-bipyridine. Derivatives of 1,10-phenanthroline forcomplexation with the osmium cation include, but are not limited to,4,7-dimethyl-1,10-phenanthroline and mono, di-, andpolyalkoxy-1,10-phenanthrolines, such as4,7-dimethoxy-1,10-phenanthroline. Polymers for complexation with theosmium cation include, but are not limited to, polymers and copolymersof poly(1-vinyl imidazole) (referred to as “PVI”) and poly(4-vinylpyridine) (referred to as “PVP”). Suitable copolymer substituents ofpoly(1-vinyl imidazole) include acrylonitrile, acrylamide, andsubstituted or quaternized N-vinyl imidazole, e.g., electron transferagents with osmium complexed to a polymer or copolymer of poly(1-vinylimidazole).

Embodiments may employ electron transfer agents having a redox potentialranging from about −200 mV to about +200 mV versus the standard calomelelectrode (SCE).

As mentioned above, the sensing layer may also include a catalyst whichis capable of catalyzing a reaction of the analyte. The catalyst mayalso, in some embodiments, act as an electron transfer agent. When theanalyte of interest is glucose, a catalyst such as a glucose oxidase,glucose dehydrogenase (e.g., pyrroloquinoline quinone (PQQ), dependentglucose dehydrogenase or oligosaccharide dehydrogenase, flavine adeninedinucleotide (FAD) dependent glucose dehydrogenase, or nicotinamideadenine dinucleotide (NAD) dependent glucose dehydrogenase) may be used.A lactate oxidase or lactate dehydrogenase may be used when the analyteof interest is lactate. Laccase may be used when the analyte of interestis oxygen or when oxygen is generated or consumed in response to areaction of the analyte.

In certain embodiments, a catalyst may be attached to a polymer, crosslinking the catalyst with another electron transfer agent which, asdescribed above, may be polymeric. A second catalyst may also be used incertain embodiments. This second catalyst may be used to catalyze areaction of a product compound resulting from the catalyzed reaction ofthe analyte. The second catalyst may operate with an electron transferagent to electrolyze the product compound to generate a signal at theworking electrode. Alternatively, a second catalyst may be provided inan interferent-eliminating layer to catalyze reactions that removeinterferents.

Certain embodiments include a Wired Enzyme™ sensing layer (such as usedin the FreeStyle Navigator® continuous glucose monitoring system byAbbott Diabetes Care Inc.) that works at a gentle oxidizing potential,e.g., a potential of about +40 mV. This sensing layer uses an osmium(Os)-based mediator designed for low potential operation and is stablyanchored in a polymeric layer. Accordingly, in certain embodiments thesensing element is redox active component that includes (1) Osmium-basedmediator molecules attached by stable (bidente) ligands anchored to apolymeric backbone, and (2) glucose oxidase enzyme molecules. These twoconstituents are crosslinked together.

In certain embodiments, the sensing system detects hydrogen peroxide toinfer glucose levels. For example, a hydrogen peroxide-detecting sensormay be constructed in which a sensing layer includes enzymes such asglucose oxidase, glucose dehydrogenase, or the like, and is positionedproximate to the working electrode. The sensing layer may be covered byone or more layers, e.g., a membrane that is selectively permeable toglucose. Once the glucose passes through the membrane, it may beoxidized by the enzyme and reduced glucose oxidase can then be oxidizedby reacting with molecular oxygen to produce hydrogen peroxide.

Certain embodiments include a hydrogen peroxide-detecting sensorconstructed from a sensing layer prepared by crosslinking two componentstogether, for example: (1) a redox compound such as a redox polymercontaining pendent Os polypyridyl complexes with oxidation potentials ofabout +200 mV vs. SCE, and (2) periodate oxidized horseradish peroxidase(HRP). Such a sensor functions in a reductive mode; the workingelectrode is controlled at a potential negative to that of the Oscomplex, resulting in mediated reduction of hydrogen peroxide throughthe HRP catalyst.

In another example, a potentiometric sensor can be constructed asfollows. A glucose-sensing layer is constructed by crosslinking together(1) a redox polymer containing pendent Os polypyridyl complexes withoxidation potentials from about −200 mV to +200 mV vs. SCE, and (2)glucose oxidase. This sensor can then be used in a potentiometric mode,by exposing the sensor to a glucose containing solution, underconditions of zero current flow, and allowing the ratio ofreduced/oxidized Os to reach an equilibrium value. The reduced/oxidizedOs ratio varies in a reproducible way with the glucose concentration,and will cause the electrode's potential to vary in a similar way.

The components of the sensing layer may be in a fluid or gel that isproximate to or in contact with the working electrode. Alternatively,the components of the sensing layer may be disposed in a polymeric orsol-gel matrix that is proximate to or on the working electrode.Preferably, the components of the sensing layer are non-leachablydisposed within the sensor. More preferably, the components of thesensor are immobilized within the sensor.

Examples of sensing layers that may be employed are described in U.S.patents and applications noted herein, including, e.g., in U.S. Pat.Nos. 5,262,035, 5,264,104, 5,543,326, 6,605,200, 6,605,201, 6,676,819and 7,299,082, the disclosures of each of which are incorporated hereinby reference for all purposes.

Regardless of the particular components that make up a given sensinglayer, a variety of different sensing layer configurations may be used.In certain embodiments, the sensing layer covers the entire workingelectrode surface, e.g., the entire width of the working electrodesurface. In other embodiments, only a portion of the working electrodesurface is covered by the sensing layer, e.g., only a portion of thewidth of the working electrode surface. Alternatively, the sensing layermay extend beyond the conductive material of the working electrode. Insome cases, the sensing layer may also extend over other electrodes,e.g., over the counter electrode and/or reference electrode (orcounter/reference is provided), and may cover all or only a portionthereof.

In other embodiments the sensing layer is not deposited directly on theworking electrode. Instead, the sensing layer may be spaced apart fromthe working electrode, and separated from the working electrode, e.g.,by a separation layer. A separation layer may include one or moremembranes or films or a physical distance. In addition to separating theworking electrode from the sensing layer the separation layer may alsoact as a mass transport limiting layer, and/or an interferenteliminating layer, and/or a biocompatible layer.

In certain embodiments which include more than one working electrode,one or more of the working electrodes may not have a correspondingsensing layer, or may have a sensing layer which does not contain one ormore components (e.g., an electron transfer agent and/or catalyst)needed to electrolyze the analyte. Thus, the signal at this workingelectrode may correspond to background signal which may be removed fromthe analyte signal obtained from one or more other working electrodesthat are associated with fully-functional sensing layers by, forexample, subtracting the signal.

Whichever configuration of the sensing component or layer is employed,at least one factor in minimizing variations in sensor sensitivity, atleast within the same sensor batch or lot (or all sensors made accordingto the same specification), is by strictly maintaining the dimensions(width, length, diameter and thickness) of the active area, i.e., thearea of the working electrode in contact with the sensing component orlayer, from sensor to sensor. Optimizing sensitivity, includingreproducing substantially the same sensitivity for sensors within a lotor batch of sensors, reduces and in certain embodiments eliminates theneed for sensor calibration, by the user. Accordingly, sensors that donot require a user to calibrate, using for example an in vitro teststrip or the like after insertion of the sensor into the body fortesting, are achieved. Examples of sensors for use in one or moreembodiments of the present disclosure can be found in, among others,U.S. patent application Ser. No. 12/714,439, the disclosure of which isincorporated herein by reference for all purposes.

Calibration, when an electrochemical glucose sensor is used, generallyinvolves converting the raw current signal (nA) into a glucoseconcentration (mg/dL). One way in which this conversion is done is byrelating or equating the raw analyte signal with a calibrationmeasurement (i.e., with a reference measurement), and obtaining aconversion factor (raw analyte signal/reference measurement value). Thisrelationship is often referred to as the sensitivity of the sensor,which, once determined, may then be used to convert sensor signals tocalibrated analyte concentration values, e.g., via simple division (rawanalyte signal/sensitivity=calibrated analyte concentration). Forexample, a raw analyte signal of 10 nA could be associated with acalibration analyte concentration of 100 mg/dL, and thus, a subsequentraw analyte signal of 20 nA could be converted to an analyteconcentration of 200 mg/dL, as may be appropriate for a given analyte,such as glucose, for example.

There are many ways in which the conversion factor may be obtained. Forexample, the sensitivity factor can be derived from a simple average ofmultiple analyte signal/calibration measurement data pairs, or from aweighted average of multiple analyte signal/calibration measurement datapairs. Further by way of example, the sensitivity may be modified basedon an empirically derived weighting factor, or the sensitivity may bemodified based on the value of another measurement, such as temperature.It will be appreciated that any combination of such approaches, and/orother suitable approaches, is contemplated herein.

For subcutaneous glucose sensors, calibration at the site ofmanufacture, that may be relied upon to calibrate sensor signal for theuseful life of a sensor, presents numerous challenges to thefeasibility. This infeasibility may be based on any of a number offactors. For example, variations in the within-lot sensitivity of theanalyte sensors and/or variations in sensor drift may be too great.

The present disclosure provides sensor embodiments which attempt toaddress both the in vivo environmental effects and themanufacturing-based inconsistencies which can lead to variation insensor sensitivity, and/or which obviate the need for any form ofcalibration, whether at the factory or by the user, at anytime prior toor during operative use of the sensor.

Certain of these sensor embodiments are double-sided, i.e., both sidesof the sensor's substrate are electrochemically functional, with eachside providing at least one electrode. Because both sides of the sensorare utilized, the smaller the necessary surface area required per sideto host the electrodes. This space-efficient construct allows the sensorto be miniaturized and much smaller than conventional sensors, and, inparticular, have a relatively narrower tail portion, i.e., at least theportion of a sensor that is constructed to be positioned beneath a skinsurface of a user is miniaturized. A narrower structure reduces traumato tissue at the implantation site, thereby reducing bleeding and theproduction of thrombi around the sensor. The smaller structure alsominimizes impingement upon adjacent blood vessels. The smaller width ofthe sensor allows, in addition to perpendicular diffusion of the analyte(e.g., glucose), for the lateral diffusion of analyte molecules towardsthe active sensing area. These effects substantially if not completelyeliminate spurious low readings.

In addition to providing micro tail sections, these double-sided sensorsare designed and configured to be highly reproducible. Further, they maybe fabricated by methods, techniques and equipment which minimizeinconsistencies in the registration, deposition and resolution of thesensor components, as described herein.

Referring now to FIGS. 6A-6C, an example of such a double-sided sensorin which an implantable portion of the sensor 600, e.g., the distalportion of the sensor's tail section, is illustrated. In particular,FIGS. 6A and 6B provide top and bottom views, respectively, of tailsection 600 and FIG. 6C provides a cross-sectional side view of the sametaken along lines C-C in FIG. 6A.

Sensor tail portion 600 includes a substrate 602 (see FIG. 6C) having atop conductive layer 604 a which substantially covers the entirety ofthe top surface area of substrate 602, i.e., the conductive layersubstantially extends the entire length of the substrate to distal edge612 and across the entire width of the substrate from side edge 614 a toside edge 614 b. Similarly, the bottom conductive layer 604 bsubstantially covers the entirety of the bottom side of the substrate oftail portion 600. However, one or both of the conductive layers mayterminate proximally of distal edge 612 and/or may have a width which isless than that of substrate 602 where the width ends a selected distancefrom the side edges 614 a, 614 b of the substrate, which distance may beequidistant or vary from each of the side edges.

One of the top or bottom conductive layers, here, top conductive layer604 a, serves as the sensor's working electrode. The opposing conductivelayer, here, bottom conductive layer 604 b, serves as a reference and/orcounter electrode. Where conductive layer 604 b serves as either areference or counter electrode, but not both, a third electrode mayoptionally be provided on a surface area of the proximal portion of thesensor (not shown). For example, conductive layer 604 b may serve asreference electrode and a third conductive trace (not shown), presentonly on the non-implantable proximal portion of the sensor, may serve asthe sensor's counter electrode.

Disposed over a distal portion of the length of conducting layer/workingelectrode 604 a is sensing component or layer 606. Providing the sensinglayer closer to the distal tip of the sensor places the sensing materialin the best position for contact with the analyte-containing fluid. Asonly a small amount of sensing material is required to facilitateelectrooxidization or electroreduction of the analyte, positioning thesensing layer 606 at or near the distal tip of the sensor tail reducesthe amount of material needed. Sensing layer 606 may be provided in acontinuous stripe/band between and substantially orthogonal to thesubstrate's side edges 614 a, 614 b with the overlap or intersection ofworking electrode 604 a and the sensing layer 606 defining the sensor'sactive area. Due to the orthogonal relationship between sensing layer606 and conductive layer 604 a, the active area has a rectilinearpolygon configuration; however, any suitable shape may be provided. Thedimensions of the active area may be varied by varying either or both ofthe respective width dimensions of the sensing and conducting layers.The width W_(S) of the sensing layer 606 may cover the entire length ofthe working electrode or only a portion thereof. As the width W_(C) ofthe conductive layer is dictated by the width of the tail portion'ssubstrate in this embodiment, any registration or resolutioninconsistencies between the conductive layer and the substrate areobviated. In certain embodiments, the width of the sensing layer W_(S)is in the range from about 0.05 mm to about 5 mm, e.g., from about 0.1mm to about 3 mm; the width of the conductive layer W_(C) is in therange from about 0.05 mm to about 0.6 mm, e.g., from about 0.1 mm toabout 0.3 mm, with the resulting active area in the range from about0.0025 mm² to about 3 mm², e.g., from about 0.01 mm² to about 0.9 mm².

Referring again to the electrodes, the same materials and methods may beused to make the top and bottom electrodes, although different materialsand methods may also be used. With the working and reference electrodespositioned on opposing sides of the substrate as in the illustratedembodiment of FIGS. 6A-6C, it is not additionally inconvenient to usetwo or more different types of conductive material to form therespective electrodes as only one type of conductive material would needto be applied to each side of the substrate, thereby reducing the numberof steps in the manufacturing process.

Selection of the conductive materials for the respective electrodes isbased in part on the desired rate of reaction of the sensing layer'smediator at an electrode. In some instances the rate of reaction for theredox mediator at the counter/reference electrode is controlled by, forexample, choosing a material for the counter/reference electrode thatwould require an overpotential or a potential higher than the appliedpotential to increase the reaction rate at the counter/referenceelectrode. For example, some redox mediators may react faster at acarbon electrode than at a silver/silver chloride (Ag/AgCl) or goldelectrode. However, as Ag/AgCl and gold are more expensive than carbon,it may be desirous to use the former materials judiciously.

The sensor embodiment of FIGS. 6A-6C provides such a construct in whichthe full-length conductive layers 604 a, 604 b may be of a material suchas carbon with a secondary layer of conductive layer 610 of a materialsuch as Ag/AgCl disposed over a distal portion of bottom conductivelayer 604 b to collectively form the sensor's reference electrode. Aswith sensing layer 606, conductive material 610 may be provided in acontinuous stripe/band between and substantially orthogonal to thesubstrate's side edges 614 a, 614 b. While layer 610 is shown positionedon substrate 602 proximally of sensing layer 606 (but on the oppositeside of the substrate), layer 610 may be positioned at any suitablelocation on the tail portion 600 of the reference electrode 604 b. Forexample, as illustrated in FIGS. 7A-7C, the secondary conductivematerial 710 of reference electrode 708 b may be aligned with and/ordistal to sensing layer 706 with dimensions W_(S) and W_(C).

Referring again to sensor 600, an insulation/dielectric layer 608 a, 608b is disposed on each side 600 a, 600 b of the sensor, over at least thesensor's body portion (not shown), to insulate the proximal portion ofthe electrodes, i.e., the portion of the electrodes which in partremains external to the skin upon implantation. The top dielectric layer608 a disposed on the working electrode 604 a may extend distally to butpreferably not over any portion of sensing layer 606. Alternatively, asillustrated in FIGS. 7A-7C, dielectric layer 708 a on the workingelectrode side of the sensor 700 may be provided prior to sensing layer706 whereby the dielectric layer 708 a has at least two portions spacedapart from each other on conductive layer 704 a, best illustrated inFIG. 7C. FIG. 7C provides a cross-sectional side view taken along linesC-C in FIG. 7A. The sensing material 706 is then provided in the spacingbetween the two portions.

As for the dielectric layer on the bottom/reference electrode side ofthe sensor, it may extend any suitable length of the sensor's tailsection, i.e., it may extend the entire length of both of the primaryand secondary conductive layers or portions thereof. For example, asillustrated in FIGS. 6A-6C, bottom dielectric layer 608 b extends overthe entire bottom surface area of secondary conductive material 610 butterminates proximally of the distal edge 612 of the length of theprimary conductive layer 604 b. It is noted that at least the ends ofthe secondary conductive material 610 which extend along the side edges614 a, 614 b of the substrate 602 are not covered by dielectric layer608 b and, as such, are exposed to the in vivo environment when inoperative use. In contrast, as illustrated in FIGS. 7A-7C, bottomdielectric layer 708 b has a length which terminates proximally ofsecondary conductive layer 710 on bottom primary conductive layer 704 balong substrate 702. Additional conducting and dielectric layers may beprovided on either or both sides of the sensors, as described above.

Finally, one or more membranes, which may function as one or more of ananalyte flux modulating layer and/or an interferent-eliminating layerand/or biocompatible layer, discussed in greater detail below, may beprovided about the sensor, e.g., as one or more of the outermostlayer(s). In certain embodiments, as illustrated in FIG. 6C, a firstmembrane layer 616 may be provided solely over the sensing component orsensing layer 606 on the working electrode 604 a to modulate the rate ofdiffusion or flux of the analyte to the sensing layer. For embodimentsin which a membrane layer is provided over a single component/material,it may be suitable to do so with the same striping configuration andmethod as used for the other materials/components. Here, the stripe/bandof membrane material 616 preferably has a width greater than that ofsensing stripe/band 606. As it acts to limit the flux of the analyte tothe sensor's active area, and thus contributes to the sensitivity of thesensor, controlling the thickness of membrane 616 is important.Providing membrane 616 in the form of a stripe/band facilitates controlof its thickness. A second membrane layer 618, which coats the remainingsurface area of the sensor tail, may also be provided to serve as abiocompatible conformal coating and provide smooth edges over theentirety of the sensor. In other sensor embodiments, as illustrated inFIG. 7C, a single, homogenous membrane 718 may be coated over the entiresensor surface area, or at least over both sides of the distal tailportion. It is noted that to coat the distal and side edges of thesensor, the membrane material would have to be applied subsequent tosingulation of the sensor precursors.

Based on current sensor fabrication techniques, provision of thesensor's conductive layers can be accomplished more accurately thanprovision of the sensing layers. As such, improving upon the accuracy ofproviding the sensing component on the sensor, and thus, the accuracy ofthe resulting active area, may significantly decrease any sensor tosensor sensitivity variability and obviate the need for calibration ofthe sensor. Accordingly, the present disclosure also includes methodsfor fabricating such analyte sensors having accurately defined activeareas. Additionally, the methods provide finished sensors which aresmaller than currently available sensors with micro-dimensioned tailportions which are far less susceptible to the in situ environmentalconditions which can cause spurious low readings.

In one variation of the subject methods, web-based manufacturingtechniques are used to perform one or more steps in fabricating thesubject sensors, many of the steps of which are disclosed in U.S. Pat.No. 6,103,033. To initiate the fabrication process, a continuous film orweb of substrate material is provided and heat treated as necessary. Theweb may have precuts or perforations defining the individual sensorprecursors. The various conductive layers are then formed on thesubstrate web by one or more of a variety of techniques as describedabove, with the working and reference (or counter/reference) electrodetraces provided on opposite sides of the web. As mentioned previously,the electrode traces may be provided in channels formed in the surfaceof the substrate material; however, with the desire to provide a sensorhaving a tail portion that has the smallest functional profile possible,and particularly with the sensor tail having two functional sides, theuse of channels may not be optimal as it requires a thicker substratematerial. Also, as mentioned previously, a third, optional electrodetrace (which may function as a counter electrode, for example) may beprovided on the proximal body portion of the sensor precursors. The“primary” conductive traces provided on the area of the tail portions ofthe precursor sensors have a width dimension greater than the intendedwidth dimension of the tail portions of the finalized sensors. Theprecursor widths of these conductive traces may range from about 0.3 mmto about 10 mm including widths in range from about 0.5 mm to about 3mm, or may be even narrower. The primary conductive layers are formedextending distally along the tail section of the sensor precursors toany suitable length, but preferably extend at least to the intendeddistal edge of the finalized sensors to minimize the necessary sensortail length.

Next, the sensing layer and secondary conductive layers, if employed,are formed on the primary conductive layers on the respective sides ofthe substrates or substrate web. As discussed, each of these layers ispreferably formed in a stripe or band of the respective materialdisposed orthogonally to the length of the primary conductivelayer/sensor tail. With a single, continuous deposition process, themean width of the sensing strip is substantially constant along thesubstrate webbing, and ultimately, from sensor to sensor. The secondaryconductive layer (e.g., Ag/AgCl on the reference electrode), ifprovided, may also be formed in a continuous orthogonal stripe/band withsimilar techniques. One particular method of providing the variousstripes/band of material on the sensors is by depositing, printing orcoating the sensing component/material by means of an inkjet printingprocess (e.g., piezoelectric inkjet as manufactured by Scienion Inc. anddistributed by BioDot Inc.). Another way of applying these materials isby means of a high precision pump (e.g., those which are piston drivenor driven by peristaltic motion) and/or footed needle. The respectivestripes/bands may be provided over a webbing of sequentially alignedsensor precursors prior to singulation of the sensors or over aplurality of sensors/electrodes where the sensors have been singulatedfrom each other prior to provision of the one or more stripes/bands.

With both the sensing and conductive layers/strips having substantiallyconstant widths and provided substantially orthogonal to each other, theactive area which their intersection forms is also substantiallyconstant along both the length and width of the sensor. In suchembodiments, the active area (as well as the intersecting area of theprimary and secondary conductive layers which form the referenceelectrode) has a rectilinear polygonal shape which may be easier toprovide in a reproducible manner from sensor to sensor; however, anyrelative arrangement of the layers resulting in any suitable active areageometry may be employed.

The sensor precursors, i.e., the template of substrate material (as wellas the conductive and sensing materials if provided on the substrate atthe time of singulation), may be singulated from each other using anyconvenient cutting or separation protocol, including slitting, shearing,punching, laser singulation, etc. These cutting methods are also veryprecise, further ensuring that the sensor's active area, when dependentin part on the width of the sensor (i.e., the tail portion of thesubstrate), has very accurate dimensions from sensor to sensor.Moreover, with each of the materials (i.e., the primary and secondaryconductive materials, sensing component, dielectric material, membrane,etc.) provided with width and/or length dimensions extending beyond theintended dimensions or boundaries of the final sensors, issues withresolution and registration of the materials is minimized if notobviated altogether.

The final, singulated, double-sided sensor structures have dimensions inthe following ranges: widths from about 500 μm to about 100 μm includingwidths in range from about 300 μm to about 150 μm; tail lengths fromabout 10 mm to about 3 mm, including lengths in range from about 6 mm toabout 4 mm; and thicknesses from about 500 μm to about 100 μm includingthicknesses in range from about 300 μm to about 150 μm. As such, theimplantable portions of the sensors are reduced in size fromconventional sensors by approximately 20% to about 80% in width as wellas in cross-section. The reduced size minimizes bleeding and thrombusformation upon implantation of the sensor and impingement on adjacenttissue and vessels, thereby minimizing impediment to lateral diffusionof the analyte to the sensor's sensing component or sensing layer.

The substrate web may have precuts or perforations that provide guidancefor the final cut employed to singulate the precursors. Depending on thelayout and orientation of the sensor precursors, the singulation linesmay be at fixed or varying intervals. For example, if the orientationand spacing of the sensor precursors are serial and constant over thearea of the substrate material, the singulation lines will typically beat fixed intervals in all directions. However, where the sensors havingirregular or asymmetrical shapes (e.g., as illustrated in FIG. 5A) itmay be preferential to orient the sensor precursors in an alternating(e.g., head to toe) or in mirroring (e.g., back to back) arrangements tominimize the unused substrate material and any of the sensor materialsdeposited thereon. Where the orientation of the sensor precursors isalternating or in a mirroring arrangement, the singulation lines may notbe at fixed intervals.

Embodiments include sensor lots having very low variations insensitivity of sensors within the lot. Low sensitivity variation enablessensors that do not require calibration by a user after a sensor ispositioned in the body. Accordingly, in certain embodiments, sensor lotsare provided that have a coefficient of variation (CV) of about 5% orless, e.g., about 4.5% or less, e.g., about 4% or less, e.g., about 3%or less.

Sensors having predictable sensor in vivo sensitivity and signal areprovided. For example, sensors having predictable shelf life sensitivitydrift (the period of time between manufacture and use) and predictablein vivo sensitivity drift, including substantially no shelf and in vivosensitivity drift, are also provided. In embodiments in which sensorshave drift (e.g., where the sensor sensitivity drifts an expectedpercentage over a certain time), a drift profile is contemplated. Thisdrift profile may be contemplated by an algorithm of the monitoringsystem to determine a drift correction factor that may be applied tosensor signal to obtain a glucose measurement (mg/dL). Due, at least inpart, to the high reproducibility of the manufacturing process thatresults in low manufacturing coefficient of variation (CV), a singledrift correction factor may be used for all sensors of a given sensormanufacturing lot or batch.

In certain embodiments, sensor sensitivity may be determinedpost-fabrication by the manufacturer at the site of manufacture. This“factory-determined” sensitivity may then be used in an algorithm tocalibrate sensor signal for the useable lifetime of the sensor, negatingthe need for a user to obtain a reference value, e.g., from a teststrip, for calibration. Sensitivity may include determining therelationship of sensor signal to a reference such as an in vitroreference (a known glucose level to which one or more sensors of asensor lot may be compared). Sensitivity may include determining aconversion factor as described herein. In certain embodiments, thedetermined sensitivity may be further augmented. For example, one ormore additional factors (e.g., to account for the relationship of bloodto subcutaneous tissue glucose, effect of oxygen, temperature, etc.) maybe contemplated. In any event, a sensitivity value is determined.Exemplary calibration protocols are described, e.g., in U.S. Pat. No.7,299,082, the disclosure of which is incorporated herein by referencefor all purposes.

Because the sensitivities of each sensor of a given manufacturing lotare substantially the same according to the embodiments herein, thefactory-determined sensitivity may be applied to all sensors of such alot, i.e., a single calibration algorithm may be used for all thesensors of a given lot. In one embodiment, the information is programmedor is programmable into software of the monitoring system, e.g., intoone or more processors. For example, the factory-determined sensitivitymay be provided to a user with a sensor(s) and uploaded to a calibrationalgorithm manually or automatically (e.g., via bar code and reader, orthe like). Calibration of sensor signal may then be implemented usingsuitable hardware/software of the system.

A mass transport limiting layer or membrane, e.g., an analyte fluxmodulating layer, may be included with the sensor to act as adiffusion-limiting barrier to reduce the rate of mass transport of theanalyte, for example, glucose or lactate, into the region around theworking electrodes. The mass transport limiting layers are useful inlimiting the flux of an analyte to a working electrode in anelectrochemical sensor so that the sensor is linearly responsive over alarge range of analyte concentrations. Mass transport limiting layersmay include polymers and may be biocompatible. A mass transport limitinglayer may provide many functions, e.g., biocompatibility and/orinterferent-eliminating, etc.

A membrane may be formed by crosslinking in situ a polymer, modifiedwith a zwitterionic moiety and a non-pyridine copolymer component. Themodified polymer may be made from a precursor polymer containingheterocyclic nitrogen groups. For example, a precursor polymer may bepolyvinylpyridine or polyvinylimidazole. Embodiments also includemembranes that are made of a polyurethane, or polyether urethane, orchemically related material, or membranes that are made of silicone, andthe like.

Optionally, another moiety or modifier that is either hydrophilic orhydrophobic, and/or has other desirable properties, may be used to“fine-tune” the permeability of the resulting membrane to an analyte ofinterest. Optional hydrophilic modifiers, such as poly(ethylene glycol),hydroxyl or polyhydroxyl modifiers, may be used to enhance thebiocompatibility of the polymer or the resulting membrane.

The membrane may also be formed in situ by applying an alcohol-buffersolution of a crosslinker and a modified polymer over anenzyme-containing sensing layer and allowing the solution to cure forabout one to two days or other appropriate time period. Thecrosslinker-polymer solution may be applied to the sensing layer byplacing a droplet or droplets of the solution on the sensor, by dippingthe sensor into the solution, or the like. Generally, the thickness ofthe membrane is controlled by the concentration of the solution, by thenumber of droplets of the solution applied, by the number of times thesensor is dipped in the solution, or by any combination of thesefactors. A membrane applied in this manner may have any combination ofthe following functions: (1) mass transport limitation, i.e., reductionof the flux of analyte that can reach the sensing layer, (2)biocompatibility enhancement, or (3) interferent reduction. Exemplarymass transport layers are described in U.S. patents and applicationsnoted herein, including, e.g., in U.S. Pat. Nos. 5,593,852, 6,881,551and 6,932,894, the disclosures of each of which are incorporated hereinby reference for all purposes.

A sensor may also include an active agent such as an anticlotting and/orantiglycolytic agent(s) disposed on at least a portion a sensor that ispositioned in a user. An anticlotting agent may reduce or eliminate theclotting of blood or other body fluid around the sensor, particularlyafter insertion of the sensor. Examples of useful anticlotting agentsinclude heparin and tissue plasminogen activator (TPA), as well as otherknown anticlotting agents. Embodiments may include an antiglycolyticagent or precursor thereof. Examples of antiglycolytic agents areglyceraldehyde, fluoride ion, and mannose.

The electrochemical sensors of the present disclosure may employ anysuitable measurement technique, e.g., may detect current, may employpotentiometry, etc. Techniques may include, but are not limited to,amperometry, coulometry, and voltammetry. In some embodiments, sensingsystems may be optical, colorimetric, and the like.

The subject analyte measurement systems may include an optional alarmsystem that, e.g., based on information from a processor, warns thepatient of a potentially detrimental condition of the analyte. Forexample, if glucose is the analyte, an alarm system may warn a user ofconditions such as hypoglycemia and/or hyperglycemia and/or impendinghypoglycemia, and/or impending hyperglycemia. An alarm system may betriggered when analyte levels approach, reach or exceed a thresholdvalue. An alarm system may also, or alternatively, be activated when therate of change, or acceleration of the rate of change, in analyte levelincrease or decrease approaches, reaches or exceeds a threshold rate oracceleration. A system may also include system alarms that notify a userof system information such as battery condition, calibration, sensordislodgment, sensor malfunction, etc. Alarms may be, for example,auditory and/or visual. Other sensory-stimulating alarm systems may beused including alarm systems which heat, cool, vibrate, or produce amild electrical shock when activated.

The subject disclosure also includes sensors used in sensor-based drugdelivery systems. The system may provide a drug to counteract the highor low level of the analyte in response to the signals from one or moresensors. Alternatively, the system may monitor the drug concentration toensure that the drug remains within a desired therapeutic range. Thedrug delivery system may include one or more (e.g., two or more)sensors, a processing unit such as a transmitter, a receiver/displayunit, and a drug administration system. In some cases, some or allcomponents may be integrated in a single unit. A sensor-based drugdelivery system may use data from the one or more sensors to providenecessary input for a control algorithm/mechanism to adjust theadministration of drugs, e.g., automatically or semi-automatically. Asan example, a glucose sensor may be used to control and adjust theadministration of insulin from an external or implanted insulin pump.

Referring now to FIGS. 8A-12B, the continuous analyte measurementsystems illustrated therein are particularly suitable for use with thedouble-sided analyte sensors disclosed herein. These systems include askin-mounted portion or assembly and a remote portion or assembly. Theskin-mounted portion includes at least the data transmitter, thetransmitter battery and electrical contacts for electrically couplingthe implanted sensor with the transmitter, and has a housing or basewhich is constructed to externally mount to the patient's skin and tomechanically and electrically couple the implanted sensor with thetransmitter. Removably held or positioned within the housing/basestructure is a connector piece having an electrical contactconfiguration which, when used with a double-sided sensor, enablescoupling of the sensor to the transmitter in a low-profile,space-efficient manner. The remote portion of the system includes atleast a data receiver and a user interface which may also be configuredfor test strip-based glucose monitoring. Various embodiments of thesesystems and methods of using them are now described in greater detail.

FIGS. 8A and 8B illustrate one embodiment of the skin-mounted portion orassembly 800 of a continuous analyte monitoring system of the presentdisclosure. Assembly 800 includes a connector or base 802 and atransmitter 804 both having rectangular or square constructs which, whenoperatively coupled together, are mounted side-by-side in the same planeon the skin. The underside of both components has an adhesive layer forsecuring to the skin surface. Connector 802 encases a conductive core orelongated member 806 extending along its length. Conductive core 806 isshown having a cylindrical configuration but may have any suitableshape. The connector body and conductive core may be made of anysuitable non-conductive and conductive materials, respectively. Toprovide a non-rigid or semi-flexible embodiment, connector body 802 orthe portion of it about the conductive core 806 may be made of aflexible or compressible material such as silicone, etc., and connectorcore 806 may be made of a conductive polymeric material, e.g.,carbon-doped silicone. The connector 802 and its connector core 806 maybe provided in two parts or halves 802 a and 802 b, whereby the system'sanalyte sensor 808, here, having two functional sides 808 a and 808 b,may be sandwiched therebetween. Each of the inner ends of core 806 abutsa respective electrode 814 a, 814 b of sensor 808. A bracket or fixture816 may be employed to clamp together or apply pressure on opposing endsof the two connector body 802/connector core 806 pieces to ensure asufficient, continuous electrical contact between connector core 806 andsensor electrodes 814 a, 814 b. The body of the connector 802 hashollowed holes or receptacles 810 a, 810 b within a side thereof whichextend to or within conductive core 806. Holes 810 a, 810 b aredimensioned and spaced for receiving corresponding conductive pins 812a, 812 b extending from an end 815 of transmitter 804. When theconnector 802 and transmitter 804 are operatively coupled, asillustrated in FIG. 8B, pins 812 a, 812 b extend within and are inelectrical communication with conductive core 806, and thus, with sensor808. The compressible, non-conductive material of connector 802 providesa substantially hermetic seal between transmitter 804 and sensor 808.The transmitter housing may house a battery (not shown) for powering thetransmitter 804, the sensor 808, and at least a portion of the system'scontrol electronics, e.g., the data processing unit, etc.

FIGS. 9A-9E illustrate another embodiment of the skin-mounted portion orassembly 900 of a continuous analyte monitoring system of the presentdisclosure. With reference to FIG. 9A, assembly 900 includes atransmitter 902 mounted atop a mounting structure or base 904, theunderside of which has an adhesive layer for securing to the skinsurface. Here, transmitter 902 has a round foot print and a convex,low-profile top surface. The transmitter housing may house a battery(not shown) for powering the transmitter 902, the sensor 906, and atleast a portion of the system's control electronics, e.g., the dataprocessing unit, etc. A raised rim 916 or similar feature on the topsurface 912 of base 904 is shaped and dimensioned to securely holdtransmitter 902 in a snap-fit configuration. Base 904 also has acentrally disposed cradle 908 on its top surface 912 for receiving andsnugly holding a connector 910. As best shown in FIG. 9B, a sidewall ofthe base 904 has an outwardly extending portion 914 which defines a slitor keyhole therein to receive a sensor 906 (as well as an insertionneedle, as will be explained below) when operatively held by connector910. An aperture (not shown) within the bottom of cradle 908 allowspassage of sensor tail 906 b upon placement of connector 910 within thecradle 908. Cradle 908 may be sized to compress the ends of theconnector 910 toward each other so as to ensure a constant electricalconnection between the connector 910 and sensor 906.

As illustrated in FIGS. 9C-9E, connector 910 has a cylindricalconfiguration having several concentric layers or materials: anon-conductive inner member 910 a, a conductive intermediate layer 910b, and an outer dielectric cover or shell 910 c. In one embodiment, thecylindrical connector is compliant, with each of its layers made ofcompliant material(s) as described with respect to the embodiment ofFIGS. 8A and 8B. The optional inner member 910 a is made of anon-conductive compliant or substantially rigid material which extendsthrough a hole 906 c at the proximal end 906 a of sensor 906 and, thus,acts as an alignment pin. The terminal ends of the working and referenceelectrodes of double-sided sensor 906 form a conductive area or ring 906d about hole 906 c. Conductive ring 906 d may be made of gold or anotherhighly conductive material. The connector's intermediate layer 910 b ismade of a compliant conductive material, such as a conductive polymericmaterial as described with respect to the embodiment of FIGS. 8A and 8B,which abuts against both sides of conductive area 906 d of the sensor.The outer shell 910 c of the connector, which extends over and insulateseach of the conductive ends of the intermediate layer 910 b, is made ofa compliant dielectric material, such as silicone, which ensures thatthe interconnection between the transmitter, connector and sensor ishermetically sealed. On a top surface of outer shell 910 c are a pair ofbores or holes 918 for receiving a corresponding pair of pins or plugs920 extending from the bottom side of transmitter 902. The bores andpins may have respective mating configurations to ensure a snug fit andhermetically seal between transmitter 902 and connector 910. Forexample, as illustrated in FIG. 9E, bores 918 may have a steppedconfiguration and pins 920 may have a conical configuration. At leastthe distal tip 922 of each pin 920 is made of a conductive material,such as gold, to establish electrical communication between transmitter902 and sensor 906.

FIGS. 10A-10F illustrate various steps in a method of the presentdisclosure for mounting the continuous analyte monitoring system'son-skin assembly 900, including implanting sensor 906 within the skin,utilizing an insertion device 1000 of the present disclosure. However,the sensor/connector may be configured to be manually inserted/mountedwithout the use of an insertion device.

Insertion device 1000 comprises a body 1002 having a distal base portion1008 having a bottom surface configured for placement on the skinsurface 1005. It is noted that the figures show, with solid drawinglines, components of the insertion device and the analyte monitoringsystem that would otherwise not be visible when positioned or housedwithin device body 1002 for purposes of illustration and ease ofdescription. For example, in FIGS. 10A-10C, mounting base 904 ofassembly 900 (FIG. 9A) is shown releasably held within an opening in thebottom surface of device body 1002. Insertion device 1000 furtherincludes a plunger mechanism 1004 positioned within the housing 1002 andmovable in a direction perpendicular to the skin surface 1005. Thedistal end of the plunger mechanism 1004 carries an insertion needle1006. The components of insertion device 1000 are typically formed usingstructurally rigid materials, such as metal or rigid plastic. Preferredmaterials include stainless steel and ABS(acrylonitrile-butadiene-styrene) plastic.

With reference to FIGS. 11A and 11B, the shaft of insertion needle 1006may include a longitudinal opening, having a cross-sectional shape forreleasably carrying the forward edge 906 e of the analyte sensor (seeFIG. 11B). In particular, the needle shaft 1006 may be C-, U- orV-shaped to support the sensor and limit the amount that the sensor maybend or bow during insertion. The cross-sectional width and height ofinsertion needle 1006 are appropriately sized to hold the sensor beinginserted. In the illustrated embodiment, insertion needle 1006 ispointed and/or sharp at the tip 1012 to facilitate penetration of theskin of the patient. A sharp, thin insertion needle may reduce pain feltby the patient upon insertion of the sensor. In other embodiments, thetip of the insertion needle has other shapes, including a blunt or flatshape. These embodiments may be particularly useful when the insertionneedle is not intended to penetrate the skin but rather serves as astructural support for the sensor as the sensor is pushed into the skin.As such, the sensor itself may include optional features to facilitateinsertion. For example, sensor 906 may have a pointed tail portion 906 bto ease insertion. In addition, the sensor may include a barb (notshown) which helps retain the sensor in the subcutaneous tissue uponinsertion. The sensor may also include a notch (not shown) that can beused in cooperation with a corresponding structure (not shown) in theinsertion needle to apply pressure against the sensor during insertion,but disengage as the insertion needle is removed.

To commence the sensor insertion/transmitter mounting procedure, thefront edge 906 e (see FIGS. 11A and 11B) of sensor 906, which isoperatively held within connector 910 (as shown in FIG. 9B but notevident in the side views provided in FIGS. 10A-10F), is slid intoplaced within insertion needle 1006. In turn, the pre-loaded insertionneedle 1006 is operatively loaded onto the distal end of plunger 1004.Mounting base 904 with the attached connector cradle 908 is then coupledto the bottom end of insertion body 1002, such as by a snap-fitarrangement that is releasable upon complete downward displacement ofplunger 1004. The collective assembly is then placed on the target skinsurface 1005, as shown in FIG. 10A. The user 1010 then applies adownward force on plunger 1004, as shown in FIG. 10B, which force istransferred against insertion needle 1006 and/or sensor 906 to carry thesensor 906 into the skin 1005 of the patient. The plunger 1004 may bebiased to require a certain amount of force to avoid accidentaldepression and to provide for very fast penetration and removal of theinsertion needle from the skin. For example, a cocked or wound spring, aburst of compressed gas, an electromagnet repelled by a second magnet,or the like, may be used to provide the biasing force on plunger 1004.In one embodiment (as shown), the plunger force is applied to insertionneedle 1006, and optionally to sensor 906, to push a portion of both thesensor 906 and the insertion needle 1006 through the skin 1005 of thepatient and into the subcutaneous tissue. Alternatively, the force maybe applied only to the sensor 906, pushing it into the skin 1005, whilethe insertion needle 1006 remains stationary and provides structuralsupport to the sensor 906. In either embodiment, a hard stop to thesensor's continued penetration into the skin 1005 is provided when theconnector 910 is seated within cradle 908. Once fully depressed, plunger1004 is then released by the user 1010, as illustrated in FIG. 10C. Withthe upward spring biased placed on the plunger, the insertion needle isquickly retracted from the skin 1005 with sensor 906 remaining in thesubcutaneous tissue due to frictional forces between the sensor and thepatient's tissue. If the sensor includes the optional barb, then thisstructure may also facilitate the retention of the sensor within theinterstitial tissue as the barb catches in the tissue. Release ofplunger 1004 may also automatically decouple mounting base 904 frominsertion body 1002, or a separate trigger mechanism (not shown) may beprovided on the device to perform such function. The adhesive on theskin-contacting surface of base 904 retains it in place when theinsertion device 1000 is removed from the skin, as illustrated in FIG.10D. The insertion device 1000 is typically manufactured to bedisposable to avoid the possibility of contamination. Alternatively, theinsertion device 1000 may be sterilized and reused with only theinsertion needle being disposable. After removal of the insertion device1000 from the skin 1005, the transmitter 902 may then be manuallycoupled onto the mounting base 904, as shown in FIG. 10E. Specifically,the conductive pins 920 of transmitter 902 are positioned within thecorresponding holes 918 within connector 910 (see FIG. 9E). In analternate embodiment, the insertion device may be configured tomechanically mount the transmitter 902 which would be pre-mounted to themounting base 904. In either variation, control electronics (not shown)housed within transmitter 902 enables monitoring of glucose (or othertarget analytes) by sensor 906 and transmission of such analyte data bytransmitter 902 to the remote receiver unit (not shown) according to thepre-programmed protocols.

As mentioned previously, a battery may be provided within thetransmitter housing to power the transmitter 902 as well as to providethe necessary electrical signals to sensor 906. The battery may berechargeable/replaceable through a door (not shown) provided in thetransmitter housing. To minimize the size of the on-skin unit, thebattery may be relatively small, having only a moderately-lastingcharge, e.g., about 3-14 days more or less. In another variation, thebattery is not rechargeable or replaceable, but is disposed of alongwith the transmitter upon expiration of the battery charge. As thisarrangement is more expensive, having a battery/transmitter that has alonger-lasting charge, e.g., about 6 months to a year may be necessary;of course, the tradeoff being a larger unit. Still yet, the transmittermay be extensively reusable with the battery being disposable along withthe sensor upon expiration of the sensor's useful life, typically,between about 3 to about 14 days, in which case, the battery may be verysmall to last only as long as the sensor.

FIGS. 12A and 12B illustrate top and bottom views, respectively, of anon-skin mounting unit or base 1050 of another continuous analytemonitoring system of the present disclosure in which the battery isprovided in the mounting base rather than in the transmitter. Theconductive proximal portion 1054 a (i.e., the electrodes) of an analytesensor 1054 is positionable or positioned within a slot or slit 1066within a side wall of base 1050 with the tail portion 1054 b extendingtransversely from the base. The proximal sensor portion 1054 a liesbetween a two-piece electrical core or connector 1056 which ispermanently housed within mounting unit 1050. The connector has contacts1056 a (see FIG. 12A) which extend to a top surface 1052 of base 1050for receiving corresponding conductive pins of the transmitter (notshown). The entire base 1050 may be fabricated of a compressible,insulating material, such as silicone. Features 1064 on opposingsidewalls of the base aligned with the ends of connector 1056 arecompressible to ensure that connector 1056 maintains continuouselectrical contact with sensor 1054. Such compression features 1064 maycomprise a flexure such as a living hinge or the like. To prevent anymovement of sensor 1054 upon placement within skin tissue, an optionalalignment pin 1058 may be provided through a hole within proximal sensorportion 1054 a. The opposing ends of the alignment pin 1058 may extendbeyond the sidewalls of the base to physically engage with correspondingfeatures of the transmitter (not shown) upon coupling with the base unit1050. Also housed within base unit 1050 is a battery 1060 having high(+) and ground (−) connector contacts 1060 a, 1060 b, respectively. Asseen in FIG. 12A, the connector contacts 1056 a and battery contacts1060 a, 1060 b have receptacle configurations to matingly receivingcorresponding pin contacts of a transmitter (not shown) when mountedatop mounting base 1050. As such, electrical communication isestablished between sensor 1054 and the transmitter, and power issupplied to the transmitter and to the on-skin unit as a whole. Thecoupling between the transmitter and mounting base may be by way of asnap-fit arrangement between the pins and receptacles, which also allowsfor easy removal when replacing the base unit 1050 upon expiration ofthe battery 1060 and/or useful life of the sensor 1054 with the moreexpensive transmitter component being reusable.

All of the on-skin portions of the subject continuous monitoring systemshave a very low-profile configuration. While certain embodiments have atleast one dimension that is extremely small, other dimensions may beslightly greater to provide the necessary volume to house the variouscomponents of the on-skin units. For example, an on-skin unit may have avery low height dimension, but have relatively greater width and lengthdimensions. On the other hand, the width/length dimensions may be verysmall with the height being relatively greater. The optimal dimensionsof a particular on-skin unit may depend on where on the body the unit isintended to be mounted. One exemplary set of dimensions for an on-skinunit of the present disclosure includes a width from about 7.5 to about8.5 mm, a length from about 10 to about 11 mm, and a height from about2.5 to about 3.3 mm.

Exemplary analyte monitoring systems are described in, for example, U.S.patent application Ser. No. 12/698,124 entitled “Compact On-BodyPhysiological Monitoring Devices and Methods Thereof” and in U.S. patentapplication Ser. No. 12/730,193 entitled “Methods of Treatment andMonitoring Systems for Same”, the disclosures of each of which areincorporated herein by reference for all purposes. Exemplary methods andsystems for inserting a an analyte sensor are described in, for example,U.S. Pat. No. 6,990,366, U.S. patent application Ser. Nos. 12/698,124,12/698,129, now U.S. Pat. No. 9,402,544, and U.S. ProvisionalApplication Nos. 61/238,159, 61/238,483 and 61/249,535, the disclosuresof each of which are incorporated herein by reference for all purposes.

Although the subject sensors may be inserted anywhere in the body, it isoften desirable that the insertion site be positioned so that theon-skin sensor control unit can be concealed. In addition, it is oftendesirable that the insertion site be at a place on the body with a lowdensity of nerve endings to reduce the pain to the patient. Examples ofpreferred sites for insertion of the sensor and positioning of theon-skin sensor control unit include the abdomen, thigh, leg, upper arm,and shoulder.

In one embodiment, the subject sensors are injected between 2 to 12 mminto the interstitial tissue of the patient for subcutaneousimplantation. Preferably, the sensor is injected 3 to 9 mm, and morepreferably 5 to 7 mm, into the interstitial tissue. Other embodiments ofthe present disclosure may include sensors implanted in other portionsof the patient, including, for example, in an artery, vein, or organ.The depth of implantation varies depending on the desired implantationtarget. Sensor insertion angles usually range from about 10° to about90°, typically from about 15° to about 60°, and often from about 30° toabout 45°. The construct of the insertion device, of course, will varydepending on the desired angle of insertion.

In one embodiment, a continuous analyte measurement system may include abase unit configured for mounting on a skin surface, an analyte sensorcomprising two functional sides, a proximal portion configured forpositioning within the base unit and a distal portion configured forinsertion into the skin surface, and a conductive member positionablewithin the base unit and in electrical contact with the two functionalsides of analyte sensor.

The proximal portion of the analyte sensor may have a planarconfiguration and the conductive member may be mechanically andelectrically coupled to the two functional sides of the proximal portionof the analyte sensor.

The base unit may be compressible on opposing sides at least about theconductive member.

Furthermore, the system may include a component for compressing theopposing ends of the conductive member.

In one aspect, the component for compressing may be flexures on opposingsides of the base unit about the conductive member.

In another aspect, the component for compressing may be a clampingfixture positionable on opposing sides of the base unit about theconductive member.

In one aspect, the system may include an alignment pin extending throughthe proximal portion of the analyte sensor.

The base unit may be a non-conductive compressible material.

The non-conductive compressible material may be silicone.

The conductive connector may be a conductive compressible material.

The conductive compressible material may be carbon-doped silicone.

In a further aspect, the system may include a transmitter configured formounting to the base unit in a low-profile manner, wherein the base unitincludes a pair of receptacles for receiving a corresponding pair ofconductive pins of the transmitter, and the conductive pins contact theconductive member when the transmitter is operatively mounted to thebase unit.

The transmitter may mount with the base unit in a side-by-sideconfiguration.

The transmitter may mount atop the base unit.

The transmitter may house a battery.

The base unit may house a battery.

Moreover, the base unit may include a second pair of receptacles forreceiving a corresponding second pair of conductive pins of thetransmitter, wherein the conductive pins contact the battery when thetransmitter is operatively mounted to the base unit.

The base unit may include a cradle therein for receiving and holding theconductive member.

The cradle may compress opposing ends of the conductive member when heldwithin the cradle.

The conductive member may include a conductive core and an insulatingshell covering the conductive core.

In one aspect, the conductive member may include a non-conductive innermember within the conductive core, wherein the non-conductive innermember extends through an opening in the analyte sensor.

The base unit may include an adhesive bottom for adhering to the skinsurface.

The base unit may include an opening therein through which the distalend of the analyte sensor extends.

The distal end of the analyte sensor may extend along a sidewall of thebase unit.

Regarding methodology, the subject methods may include each of themechanical and/or activities associated with use of the devicesdescribed. As such, methodology implicit to the use of the devicesdescribed forms part of the present disclosure. Other methods may focuson fabrication of such devices. The methods that may be performedaccording to embodiments herein and that may have been described aboveand/or claimed below, the operations have been described in selectedtypographical sequences. However, the sequences have been selected andso ordered for typographical convenience and are not intended to implyany particular order for performing the operations.

As for other details of the present disclosure, materials and alternaterelated configurations may be employed as within the level of those withskill in the relevant art. The same may hold true with respect tomethod-based aspects of the present disclosure in terms of additionalacts as commonly or logically employed. In addition, though embodimentsof the present disclosure have been described in reference to severalexamples, optionally incorporating various features, the presentdisclosure is not to be limited to that which is described or indicatedas contemplated with respect to each variation of the presentembodiments. Various changes may be made to the embodiments describedand equivalents (whether recited herein or not included for the sake ofsome brevity) may be substituted without departing from the true spiritand scope of the present disclosure. Any number of the individual partsor subassemblies shown may be integrated in their design. Such changesor others may be undertaken or guided by the principles of design forassembly.

Also, it is contemplated that any optional feature of the inventivevariations described may be set forth and claimed independently, or incombination with any one or more of the features described herein.Reference to a singular item, includes the possibility that there areplural of the same items present. More specifically, as used herein andin the appended claims, the singular forms “a,” “an,” “said,” and “the”include plural referents unless the specifically stated otherwise. Inother words, use of the articles allow for “at least one” of the subjectitem in the description above as well as the claims below. It is furthernoted that the claims may be drafted to exclude any optional element. Assuch, this statement is intended to serve as antecedent basis for use ofsuch exclusive terminology as “solely,” “only” and the like inconnection with the recitation of claim elements, or use of a “negative”limitation. Without the use of such exclusive terminology, the term“comprising” in the claims shall allow for the inclusion of anyadditional element—irrespective of whether a given number of elementsare enumerated in the claim, or the addition of a feature could beregarded as transforming the nature of an element set forth in theclaims. Stated otherwise, unless specifically defined herein, alltechnical and scientific terms used herein are to be given as broad acommonly understood meaning as possible while maintaining claimvalidity.

In all, the breadth of the present disclosure is not to be limited bythe examples provided.

1. (canceled)
 2. A continuous analyte measurement system, comprising: amemory; a base unit configured for mounting on a skin surface; ananalyte sensor comprising a proximal portion configured for positioningwithin the base unit and a distal portion configured for insertionthrough the skin surface, wherein the analyte sensor is configured togenerate one or more signals related to an analyte level; and aconductive member positionable within the base unit and in electricalcontact with the analyte sensor; wherein the continuous analytemeasurement system is configured to determine the analyte level using atleast a drift correction factor associated with a sensor manufacturingbatch or lot and programmed into the memory of the continuous analytemeasurement system prior to insertion of the distal portion of thesensor through the skin surface.
 3. The system of claim 2, wherein atleast the proximal portion of the analyte sensor has a planarconfiguration and wherein the conductive member is mechanically andelectrically coupled to the analyte sensor.
 4. The system of claim 2,wherein the base unit is compressible on opposing sides at least aboutthe conductive member, or comprises a component for compressing theopposing ends of the conductive member.
 5. The system of claim 4,wherein the component for compressing comprises flexures on opposingsides of the base unit about the conductive member or else comprises aclamping fixture positionable on opposing sides of the base unit aboutthe conductive member.
 6. The system of claim 2, further comprising analignment pin extending through the proximal portion of the analytesensor.
 7. The system of claim 2, wherein the base unit comprises anon-conductive compressible material, comprising silicone.
 8. The systemof claim 2, wherein the conductive member comprises a conductivecompressible material, comprising carbon-doped silicone.
 9. The systemof claim 2, further comprising a transmitter configured for mounting tothe base unit in a low-profile manner, wherein the base unit furthercomprises a first pair of receptacles for receiving a correspondingfirst pair of conductive pins of the transmitter, wherein the conductivepins contact the conductive member when the transmitter is operativelymounted to the base unit.
 10. The system of claim 9, wherein thetransmitter is configured to mount with the base unit in a side-by-sideconfiguration or atop the base.
 11. The system of claim 9, wherein thetransmitter or the base unit houses a battery.
 12. The system of claim11, wherein the base unit houses the battery, and wherein the base unitfurther comprises a second pair of receptacles for receiving acorresponding second pair of conductive pins of the transmitter, whereinthe conductive pins contact the battery when the transmitter isoperatively mounted to the base unit.
 13. The system of claim 2, whereinthe base unit comprises a cradle therein for receiving and holding theconductive member, wherein the cradle compresses opposing ends of theconductive member when held within the cradle; wherein the conductivemember comprises a conductive core and an insulating shell covering theconductive core; wherein the conductive member further comprises anonconductive inner member within the conductive core; and wherein thenon-conductive inner member extends through an opening in the analytesensor.
 14. The system of claim 2, wherein the base unit comprises anadhesive bottom for adhering to the skin surface or wherein the baseunit comprises an opening therein through which the distal portion ofthe analyte sensor extends.
 15. The system of claim 2, wherein thedistal portion of the analyte sensor extends along a sidewall of thebase unit.
 16. The system of claim 2, wherein the analyte sensor doesnot require a user-initiated calibration during in vivo use of theanalyte sensor.
 17. The system of claim 2, wherein the analyte sensorcomprises a plurality of electrodes including a working electrodecomprising an analyte-responsive enzyme bonded to a polymer disposed onthe working electrode.
 18. The system of claim 17, wherein theanalyte-responsive enzyme is chemically bonded to the polymer.
 19. Thesystem of claim 17, wherein the working electrode further comprises amediator.
 20. The system of claim 2, wherein the analyte sensorcomprises a plurality of electrodes including a working electrodecomprising a mediator bonded to a polymer disposed on the workingelectrode.
 21. The system of claim 20, wherein the mediator ischemically bonded to the polymer.